Method and device for producing a 3-D substrate coated with a laminate

ABSTRACT

A forming tool is used, which has a tool trough arranged in a stationary manner and a pressure bell, which can be lowered onto and lifted away from the tool trough. An arrangement is created in which a single- or multi-layer, initially flat, flexible laminate separates the trough interior from the pressure-bell interior in a pressure tight manner. A table, on which the 3-D substrate to be coated is located, assumes a lowered position within the trough interior; there is a considerable, free intermediate space (between the laminate and the 3-D substrate. A radiant-heater assembly is inserted into said intermediate space. The radiant-heater assembly has a carrier, on the top side of which radiant heaters that can be activated are attached and on the bottom side of which radiant heaters that can be activated are attached.

RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser.15/921,167 filed on Mar. 14, 2018 which is a continuation ofInternational Application PCT/EP2016/001536 filed on Sep. 12, 2016claiming priority from German Application DE 10 2015 012 242.8 filed onSep. 18, 2015, all of which are incorporated by their entirety by thisreference.

FIELD OF THE INVENTION

The instant invention relates to a method for producing a 3D-substratethat is coated with a laminate. The invention furthermore relates to adevice for performing the method.

The term 3D-substrate designates an element with a three dimensionalsurface contour. The laminate can be configured with one layer or withplural layers. A typical advantageous laminate includes at least oneplastic foil which can be e.g. made from Polycarbonate (PC),Acrylnitril-Butadien-Styrol-Terpolymeres (ABS), PC/ABS-blends,Poly(meth)acrylate (PMMA), Polyester (PE), Polyamide (PA), Polypropylene(PP), Polyarylsulfon (PSU) or Polyvinylchloride (PVC).

Coating with a laminate of this type provides an esthetic appearance tothe 3D-substrate and increases its utility. Products produced by themethod according to the invention are e.g. interior furnishingcomponents for motor vehicles, elements of motor vehicle bodies likee.g. spoilers and bumpers, applications and other components offurniture like housings and/or components of other decorative highquality consumer products.

BACKGROUND OF THE INVENTION

Takayuki MIURA describes in NIHON GAZO GAKKAISHI (Journal of the ImagingSociety of Japan), Volume 48 (2009), Number 4, pages 277-284 “TheDevelopment and Progress of the Three-Dimensional Overlay Method (TOM)”.In the art this method is designated as TOM-process. This articlerecites among other things:

4. applying a decorative coating

4.1 a three dimensional coating or overlay-method (Three dimensionOverlay Method=TOM method).

This article is a general introduction into thermal forming. When themold is replaced by the object to be decorated or the “substrate” in thethermal forming process one arrives at the “TOM-Process”, namely at asurface decorating method using a laminate;

The TOM-process originates from the forming method, “NGF” (“NGF” standsfor Next Generation Forming”). The TOM-Process and its execution will bedescribed infra.

Initially a support for receiving the substrate is placed on the tablein the lower tool half of a “NGF”-Forming tool. The substrate is placedinto the support (c.f. FIG. 17).

The laminate is arranged on top of the substrate in a laminate formingposition. The laminate used has a particular thee layer configuration,namely a skin made from a thermoplastic foil, an intermediary layer madefrom a decorative layer, thus an imprinted foil or another coatingmaterial and a rear layer made from a glue layer (c.f. FIG. 18).

This laminate is subjected to the typical NGF forming. For this purposethe upper tool half is lowered; the pressure is lowered in an interiorof the upper tool half and in an interior of the lower tool half(decompression); the radiation heaters in the upper tool half areactivated (heating); the table arranged in the lower tool half with thesubstrate arranged thereon is raised (thrusting up the mold); ambientair or compressed air is only introduced into the interior (pressurebell) of the upper tool half in order to apply the layer material to thesubstrate; (c.f. FIG. 19); and the product is retrieved in a conditionwhere the skin of the laminate is glued to the substrate (c.f. FIG. 20).

Thereafter unnecessary portions of the layer material are removed (c.f.FIG. 21).

Through this method also undercuts at the substrate can be coated andrecesses and pockets in the substrate surface can be lined which was notpossible with prior decorating methods.

The statements cited supra are also provided in the Japanese Patent JP03937231 B.

The Japanese publication document JP 2006225229 A relates to a methodand a device for producing a transparent object. A palette made fromtransparent plastic material shall be applied in a simple and easymanner through a transparent synthetic resin glue at a mineral glassplate. More in detail hot forming of a transparent plastic plate isdisclosed, for example of a 5 mm polycarbonate plate and connecting theheated plate with a surface that is provided with an activated glue of acambered plate made from mineral glass that is for example 2 mm thickfor generating a wind screen for a motor vehicle. During the joining theglass plate joins a mold that can have the same contour and which can bemade from metal. The heating of the plastic plate that is clamped withina housing and vertically oriented is performed between 2 mobilevertically oriented heat radiator arrangements that are configured withIR heat radiators which are lifted up from a vertically oriented returnspace that is arranged below the housing until they have come intomatching alignment with the vertically oriented plastic plate.Thereafter the two heat radiator arrangements are lowered again intotheir return spaces that are arranged parallel adjacent to each otherand the heated plastic plate is formed onto the glass plate by an airpressure difference and pressed into contact wherein the glass plate issupported by the mold and provided with glue.

The document DE 10 2010 021 892 B4 relates to a method and a devicecoating a 3D-carrier element with a laminate and cites additionalpertinent art.

Arrangements for performing the TOM-Process are meanwhile commerciallyavailable, e.g. from

Fu-Se Vacuum Forming Ltd., 2-103 Komagatani, Habikino-shi, JAPAN.

The current Model NGF-0512-S has been examined by applicant in spring of2015. This model implements a lab or prototype standard. Considerableinterference of an operator is required for example for applying thelayer material at the forming tool, for activating a heater in theclosed pressure bell and for activating additional machine function. Acoating cycle takes at least 300 seconds or more.

BRIEF SUMMARY OF THE INVENTION

Improving upon the art recited supra it is an object of the invention toprovide a method for coating a 3D-substrate with a laminate that issuitable for commercial or industrial applications and that facilitatesa cycle time of less than 120 seconds, more advantageously of less than60 seconds. Additionally a compact and efficient device shall beprovided for performing the method.

Solution

A first object of the instant invention is achieved by a method forproducing a 3D-substrate that is coated with a laminate, the methodcomprising the steps: using a forming tool including a lower stationarytool half which includes a tool trough that envelops a tool troughinterior in which a lowerable table is arranged, an upper tool halfwhich includes a pressure bell that envelops an interior space, whereinthe pressure bell is arrangeable in a closed position adjacent to thetool trough and in a raised release position that is remote from thetool trough, wherein the following steps are performed in the raisedrelease position of the pressure bell: introducing a 3D-substrate thatis to be coated into the forming tool and fixing the 3D-substrate to thelowerable table in the tool trough, lowering the lowerable table to alower dead center, and arranging a one layer or multi-layer initiallyflat laminate that has a visible side and an opposite contact side or aflexible transfer foil that is provided with a blank made from thelaminate at a circumferential edge of the pressure bell or adjacentthereto, providing an arrangement in the closed position of the pressurebell, wherein the laminate or the transfer foil separates the interiorspaces arranged in both tool halves pressure tight from each other, anda pressure medium pressure of less than or equal to 30 kPa is initiallyset in the tool trough interior, and an initial vacuum of less than orequal to 30 kPa is set in the pressure bell interior space andsubsequently a pressure medium pressure of 2-18 bar is set in thepressure bell interior space by introducing a fluid pressure mediumpressure fluid, and the laminate is heated while both forming toolinterior spaces are provided with a pressure medium pressure of lessthan or equal to 30 kPa, wherein the tool trough includes at least oneretraction cavity for at least one movable heat radiator arrangementwhich includes at least one upward radiating heat radiator, and whereinthe heat radiator arrangement is moved in the closed pressure bellposition and after setting the pressure medium pressure at less than orequal to 30 kPa within the tool trough interior space from itsretraction cavity into an interior space between the laminate materialand the 3D substrate to be coated and the laminate is heated in acontrolled manner by the upward radiating heat radiators, and the heatedlaminate is applied over a glue layer to the 3D-substrate and coatedthereto, setting ambient pressure in both forming tool interior spaces,separating the two tool halves from each other, lifting the pressurebell and removing the 3D-substrate that is coated with the laminate fromthe tool trough interior and processing the laminate as required,characterized in that the glue layer provided with activatable glue isarranged at the contact side of the laminate and activated by theactivated upward radiating heat radiators also the glue arranged at thelaminate material contact side is activated, and the movable heatradiator arrangement is additionally provided with activatable downwardradiating heat radiators, and after introducing the heat radiatorarrangement into the intermediary space between the laminate materialand the 3D-substrate to be coated the surface of the 3D-substrate to becoated is heated in a controlled manner by the activated downwardradiating heat radiators and after completion of the heat treatments theheat radiator arrangement is moved back into its retraction cavity.

The object is also achieved by a device for producing a 3D-substratethat is coated with a laminate, the device including a forming toolincluding, a lower stationary tool half which includes a tool troughthat envelops a tool trough interior in which a lowerable table isarranged, an upper tool half which includes a pressure bell thatenvelops an interior space, wherein the pressure bell is arrangeable ina closed position adjacent to the tool trough and in a raised releaseposition that is remote from the tool trough, wherein an arrangement isprovidable in the raised release position of the pressure bell, whereina 3D-substrate that is to be coated is insertable into the forming tooland the 3D-substrate is fixable to the lowerable table in the tooltrough and the lowerable table is lowerable to a bottom dead center, andwherein a one layer or multi-layer initially flat laminate that has avisible side and an opposite contact side or a flexible transfer foilthat is provided with a blank made from the laminate is applicable at acircumferential edge of the pressure bell or adjacent thereto, andwherein an arrangement is providable in the closed pressure position ofthe pressure bell, wherein the laminate or the transfer foil separatesthe interior spaces arranged in both tool halves pressure tight fromeach other, wherein a pressure medium pressure of less than or equal to30 kPa is initially providable in the tool trough interior, wherein aninitial vacuum of less than or equal to 30 kPa is providable in thepressure bell interior space and subsequently a pressure medium pressureof 2-18 bar is providable in the pressure bell interior space byintroducing a fluid pressure medium, wherein the laminate is heatablewhile both forming tool interior spaces are provided with a pressuremedium pressure of less than or equal to 30 kPa, wherein the tool troughincludes at least one retraction cavity for at least one movable heatradiator arrangement which includes at least one upward radiating heatradiator, wherein the heat radiator arrangement is movable in the closedposition of the pressure bell and after the pressure medium pressure isset at less than or equal to 30 kPa within the tool trough interiorspace from its retraction cavity into an interior space between thelaminate and the 3D substrate to be coated and the laminate is heatablein a controlled manner by the upward radiating heat radiators, wherein aheated laminate is applicable over a glue layer to the 3D-substrate andcoatable thereto, wherein ambient pressure set in both forming toolinterior spaces renders the pressure bell separable from the tool troughby lifting the pressure bell from the tool trough and the 3D-substratethat is coated with the laminate is removable from the tool troughinterior and processable as required, wherein the glue layer that isprovided with activatable glue is arranged at the contact side of thelaminate and also the glue arranged at the laminate contact side isactivatable by the activated upward radiating heat radiators, whereinthe movable heat radiator arrangement is additionally provided withactivatable downward radiating heat radiators, wherein the heat radiatorarrangement is introduced into the intermediary space between thelaminate material and the 3D-substrate so that the surface of the3D-substrate is heatable in a controlled manner by the downwardradiating heat radiators, and wherein the heat radiator arrangement isretractable into its retraction cavity after completion of the heattreatments.

Improving upon a method for producing a 3D-substrate that is coated witha laminate the subsequent method steps are performed in a forming tool,

wherein the forming tool includes a lower stationary tool half, whichincludes a tool trough which envelops a tool trough interior in which alowerable table is arranged, and

wherein the forming tool includes an upper tool half which includes apressure bell enveloping an interior space, wherein the pressure bell isarrangeable in a closing position adjacent to the tool trough and in araised release position that is remote from the tool trough, wherein thefollowing steps are performed in the pressure bell release position,

introducing a 3D-substrate that is to be coated into the form tool andfixing the 3D-substrate to the lowerable table in the tool trough,lowering the lowerable table to a lower dead center,

applying a one layer or multi-layer initially flat flexible laminatethat has a visible side and an opposite contact side that is coated withan activatable glue, or a flexible transfer foil that is provided with ablank made from the laminate at the or adjacent to a circumferentialseal surface at an edge of the pressure bell, and

an arrangement is provided in this pressure bell closing position

in which the laminate or the transfer foil separates the interior spacesarranged in both tool halves pressure tight from each other, and

a pressure medium pressure of less than or equal to 30 kPa is set in thetool trough interior, and

an initial vacuum of less than or equal to 30 kPa is set in the pressurebell interior space and subsequently a pressure medium pressure of 2-18bar is set thereafter by introducing a pressure medium, in particularcompressed air

heating the laminate with a pressure medium pressure of less than 30 kPain both forming tool interior spaces, and

applying the heated laminate overt the glue layer to the 3D-substrateand coating the 3D-substrate with the laminate, and

setting ambient pressure in both forming tool interior spaces,separating the two tool halves from each other, lifting the pressurebell and removing the 3D-substrate that is coated with the laminate fromthe tool trough interior and processing it as required,

wherein the solution of technical task of the invention is characterizedin that

the tool trough includes at least one retraction cavity for at least onedisplaceable heat radiator arrangement which is provided withactivatable upward radiating heat radiators and with activatabledownward radiating heat radiators; and

in order to heat the layer material the following steps are performed bythe heat radiator arrangement;

displacing the heat radiator arrangement in the pressure bell closingposition after setting the pressure material pressure at less than orequal to 30 kPa within tool trough interior from its retraction cavityinto the intermediary space between the layer material and the3D-substrate; and

heating the layer material in a controlled manner by the activating theupward radiating heat radiator and activating the glue that is arrangedat the laminate contact side; and

heating the surface of the 3D-substrate in a controlled manner by theactivated downward heating radiators; and

moving the heat radiator arrangement back into its retraction cavityafter completing the heat treatment.

An upward radiation and a downward radiation are respectively providedin the vertical direction. Therefore when used as intended theactivatable and upward radiating heat radiators and the activatable anddownward radiating heat radiators are arranged at least one heatradiator arrangement which is oriented horizontal or substantiallyhorizontal which is moved from at least one retraction cavity that isarranged at the tool trough and oriented horizontally or substantiallyhorizontally in the intermediary space between the layer material andthe 3D-substrate to be laminated. Substantially horizontally orientedspecifies an orientation which deviates by less than 12° from thehorizontal orientation.

A temporary introduction of a heat radiators arrangement provided withupward radiating heat radiators and downward radiating heat radiatorsinto the intermediary space between the layer material and the3D-substrate provides optimum condition for heating the laminate and the3D-substrate. The upward heat radiating heat radiators can be operatedindependently from the downward radiating heat radiators and can beoperated in an optimum manner according to the requirements of thelaminate and the glue. The downward radiating heat radiators facilitatea controlled heating of the surface of the 3D-substrate which improvesreaction and adherence between the 3D-substrate surface and the glue.The entire heating process can be accelerated considerably which in turnfacilitates a reduction of cycle times.

Advantageously it is thus provided that IR flat radiators are used asheat radiators which include a metal foil configured as heat elementswhich can be made to glow when current passes through. Metal foils ofthis type reach their nominal power and operating temperature e of 800°C. within 8-10 seconds within a time period of less than 5 sec a coolingto a temperature e of 200° C. can be reached. IR flat radiators of thistype deliver high radiation intensity with short reaction times. IR flatradiators of this type are perfectly suited as heat radiator for a heatradiator arrangement which is kept with deactivated heat radiators in areturn space which is thereafter temporarily moved into the intermediaryspace between the laminate and the 3D-Substrate where the heat radiatorsare activated and which heat the laminate and the 3D-Substrate veryquickly. A sufficient heating of the layer material and activation ofthe glue is facilitated within a heating time of less than 30 second,advantageously less than 20 seconds which facilitate cycle times of lessthan 120 seconds, advantageously less than 60 seconds.

When UV hardening glues are used additional activate able UV radiatorsor UV lamps are arranged at the heat radiator arrangement. Depending ona thickness of the radiation hardening glue layer and intensity of theUV radiation a hardening can be obtained within a few seconds.

The controlled heating of the layer material and the 3D-Substrate by aheat radiator arrangement which is temporarily arranged between the tooltrough in the intermediary space between the laminate and the3D-Substrate is performed at pressure medium pressure of less than 30kPa. 30 kPa stands for 30,000 Pascal. This is 225 Torr or 300 mbar. Thesubstantial ventilation of the interior of the tool trough before thelayer material to be deformed is loaded with the pressure materialpressure of 2-18 bar has the following advantages:

a displacement of the laminate is not impeded by the air that isinitially provided in this space which typically would have to escapethrough tight channels,

air enclosures between the layer material and the 3D substrate arereduced or completely removed.

activating the glue can be performed in an environment with reducedoxygen content, gas emission that occur when activating the glue areremoved before the layer material contacts the 3D-Substrate

the adhesion and gluing strength of the layer material at the3D-Substrate is improved.

a variation width of the produce able coated products is increased and aquality of the coating is improved.

A second object of the invention relates to a device for producing a3D-substrate coated with a laminate. The device is configured inparticular to perform the method according to the invention.

Improving upon the art recited supra it is an object of the invention toprovide a device for coating a 3D-substrate with a forming tool theforming tool comprising:

a lower stationary tool half, which includes a tool trough whichenvelops a tool trough interior in which a lowerable table is arranged,and

the an upper tool half which includes a pressure bell enveloping aninterior space, wherein the pressure bell is arrangeable in a closingposition adjacent to the tool trough and in a raised release positionthat is remote from the tool trough, and in the raised release positionof the pressure bell

a 3D-substrate that is to be coated is introducible into the form tooland the 3D-substrate is fixable to the lowerable table in the tooltrough, and the lowerable table is lowerable to a lower dead center, and

a one layer or multi-layer initially flat flexible laminate that has avisible side and an opposite contact side that is coated with anactivate able glue, or a flexible transfer foil that is provided with ablank made from the laminate is arrangeable at or adjacent to acircumferential seal surface at an edge of the pressure bell, and

an arrangement is provided in this pressure bell closing position inwhich

the laminate or the transfer foil separates the interior spaces arrangedin both tool halves pressure tight from each other, and

a pressure medium pressure of less than or equal to 30 kPa is adjustablein the tool trough interior, and

a pressure medium pressure of less or equal 30 kPa is adjustable in thepressure bell interior space and a pressure medium pressure of 2-18 baris adjustable thereafter by introducing a pressure fluid, in particularcompressed air

the laminate is heatable with a pressure medium pressure of less than orequal to 30 kPa in both forming tool interior spaces, and

the heated laminate is applicable over the glue layer to the3D-substrate and coatable to the 3D-substrate, and

after ambient pressure is set in both forming tool interior spaces thetwo tool halves are separated from each other, the pressure bell israised and removing the 3D-substrate that is coated with the laminate isremoved from the tool trough interior and processed as required, whereinthe improvement according to the invention is characterized in that

the toll trough includes at least one retraction cavity for at least onedisplaceable heat radiator arrangement which is provided withactivatable upward radiating heat radiators and with activatabledownward radiating heat radiators; and

in order to heat the laminate

the heat radiator arrangement is displaceable in the pressure bellclosing position after the pressure material pressure is set at less orequal to 30 kPa within tool trough interior from its retraction cavityinto the intermediary space between the layer material and the3D-substrate; and

the layer material is heatable in a controlled manner by the activatedupward radiating heat radiators and the glue that is arranged at thelaminate contact side is activatable; and

the surface of the 3D-substrate is heatable in a controlled manner bythe activated downward heating radiators; and

the heat radiator arrangement is movable back into its return cavityafter the heat treatment is completed.

A device of this type is well suited to perform the method according tothe invention reliably. The advantages recited supra are achieved.

Additional advantages of the invention and possible improvements can bederived from the subsequent detail description. Advantageous embodimentsand improvement of the method according to the invention and the deviceaccording to the invention can be derived from the dependent claims.

Thus it can be advantageously provided that the table is moved into itsupper dead center after completing the heat treatment according to theinvention and after returning the heat radiator arrangement into itsreturn cavity, wherein the 3D-Substrate penetrates the laminate planeand moves the heated laminate along in a tent shape, while a pressuremedium pressure of less or equal 30 kPa is provided in the pressure bellinterior. Shaping the laminate and applying it to the 3D-Substratesurface is performed gradually and gently by positive forming. Thelifting speed of the table can be adapted to prevailing conditions.Excessive stretching of the layer with undesirable material migrationcan thus be avoided.

According to another advantageous embodiment of this method it isprovided at a point in time when the table has reached its upper deadcenter and the first step of the laminate forming is completed tointroduce a fluid pressure medium, in particular compressed air into thepressure bell interior space in order to adjust a pressure mediumpressure of 2-18 bar in the pressure bell interior. At this point intime a reduced pressure medium pressure of less than 30 kPa is providedat the contact side of the 3D-Substrate. The increased pressure mediumpressure impacting the laminate applies the laminate in a true andgentle manner even to finest details of the 3D-Substrate surface and thecuts can be coated reliably and recesses in the 3D-Substrate surface canbe coated in their entirety.

According to another advantageous embodiment of the method it can beprovided that loading the laminate or a transfer foil provided with thelaminate blank is continued with the increased pressure medium pressureis continued for at least 2 seconds at the same pressure medium pressureafter the laminate or the transfer foil has contacted the 3D-Substrateor the first time. Further advantageously the loading can be continuedfor 5 seconds after the laminate or the transfer foil has contacted the3D-Substrate for the first time. For example the loading of the laminateor of the transfer foil with the increased pressure material pressurecan be continued upon the applied pressure material pressure for 2-30seconds after the laminate or the transfer foil has contacted the3D-Substrate for the first time. The contact pressure of the fluidpressure medium at the laminate which is continued for several secondwithout reduction provides a safe gluing between the laminate and the3D-Substrate surface. The glue strength of the glue joint can thus beincreased.

For a 3D-substrate any object is suitable that has a 3D envelope ofshell and whose surface shall be coated with a firmly adhering layermaterial. Typically this envelope or shell is supported at a supportstructure which subsequently also provides for application andattachment of the coated product at its installation location. Carrierelement of this type can be advantageously made from metal,advantageously a light metal, thus for example AL or MG materials orfrom stable and durable plastic materials, furthermore from wood orother stable and durable and plastic materials. If the 3D-Substrate ismade from a plastic material advantageously thermal plastic materialsare suitable that can be processed by injection molding like e.g.

Polyamide (PA),

Acrylnitril-Butadien-Styrol-Terpolymers (ABS),

Acrylester-Butadien-Styrol-Terpolymer (ASA),

Polymethlenoxide (POM),

Polyvinylchloride (PVC)and

Polyarylensulfone (PSU).

One piece injection molded components are produced in advance by theinjection molding method from these and other similar materials whereinthe injection molded components are subsequently coated with a laminateaccording to the method according to the invention.

A typical laminate is made from a multi-layer composite and will includein addition to other optional laminates like e.g. metal foils, woodveneer layers, thus in particular tropical wood veneers, leather,synthetic layer like e.g. ALCANTARA (ALCANTARA® furthermore, textilematerials like e.g. woven materials, knitted materials and fleecematerials respectively made from natural fibers and/or synthetic fibersand at least one plastic foil. Plastic foils of this type can betransparent or at least partially imprinted, metalized and/or coatedotherwise. A foil composite can include clear transparent foils andcolored transparent foils which include at least partially imprintedmetalized or otherwise coated foils. The metallization on a foil canalso be provided in a form of imprinted or otherwise applied conductorpaths, advantageously along meander shaped, easily expandable lines inorder to withstand expansions of the foil without forming cracks in thenarrow conductor paths. Conductor paths of this type facilitateproviding power to LEDs which can also be integrated into the laminateor which can be arranged at the 3D-substrate.

Advantageously at least one plastic foil is provided that is made from athermoplastic material selected from a group consisting of:

Polycarbonate or Copolycarbonate based on Diphenoles,

Poly- or Copolyacrylates,

Poly- or Copolymethacrylates,

Polymers or Copolymers with Styrol, in particularAcrylnitril-Butadien-Styrol-Terpolymers,

thermoplastic Polyurethanes,

Polyolefines,

Poly- or Copolykondensates der Terephthal acid,

Polyesters e.g. (Alkyl)terephthalates or (Alkyl)naphthenates,

and mixes and blends from these materials.

Advantageously a plastic foil is used which has a layer thickness of 20μm to 1000 μm particularly advantageously of 50 μm to 500 μm. Furtheradvantageously a plastic foil which has a structured surface on avisible side that is oriented away from the 3D-Substrate can be used.Particular decorative effects can be obtained.

Activatable glues are used for the method according to the invention.Thermally activate able glue compounds can be used or UV hardening gluecompounds or thermally activate able in radiation hardening gluecompounds. Thermally activate able glue compounds advantageously have anactivation temperature e in a range of 60° to 140°, furtheradvantageously an activation temperature e of 75° to 130° C. suitablethermally activate able glue compounds are described e.g. in the gluecompounds DE 10 2006 042 816 A1. The thermally activatable gluecompounds described therein are advantageously used.

UV hardening for glue compounds are described in the document DE 103 21585 A1. They typically include polymers made from (meth)acrylates,urethanacrylates, epoxyacrylates and their compounds. Polymers of thistype can include one or plural free photo initiators of one or pluralco-polymerizable photo initiators and/or one or plural photo initiatorsthat are already included in the oligomer or polymer. The photohardening is performed by actinic radiation. Thus, compounds that formradicals under UV light trigger a UV initiated polymerization. Dependingon the intensity of the UV radiation and the layer thickness of the UVhardening glue compound, sufficient hardening can be obtained within afew seconds. UV hardening glue compounds for foils are well known andcommercially available. The actinic radiation required for UV hardeningcan be advantageously generated and provided by UV LED systems that canbe switched on and off quickly.

The laminate has a visible side that his remote from the 3 D carrierelement and a contact side that is adjacent to the 3D-Subtrate. Theactivatable glue compound is only applied on the contact side of thelaminate. The activatable glue compound can be applied to the initiallyflat laminate by silk screening, transfer printing, direct coating orsimilar. The amount, layer thickness and distribution of the appliedglue compound can be controlled easily and adapted to the gluingrequirements of a 3D-Substrate with a particular shape. Using the upwardradiating heat radiators and optionally UV radiators at the heatradiator arrangement that is inserted into the intermediary spacebetween the laminate and the 3D-Substrate facilitates heating andactivating the glue compound that is applied to the contact side of thelaminate for example with a thickness of 20-50 μm can be heated upquickly and in a precisely controlled manner. The activated gluecompound layer is applied to the 3-D substrate surface that is alsoheated in a targeted and controlled manner. An optimum gluing with goodadhesion can be obtained alternatively solvent free melt glues based onthermoplastic urethanes which are available in the form of melt glueforms or fleeces can be applied in a controlled manner to the contactside of the laminate and activated thermally and/or using actinicradiation.

According to another advantageous embodiment of the method according tothe invention a laminate blank that is tailored to the 3D-Substate isplaced on a transfer foil. Only the transfer foil is clamped between the2 seal surfaces of the pressure bell and the tool trough so that thetool halves are separated from each other pressure tight. When loadedwith the fluid pressure medium at an increased pressure medium pressureof 2-18 bar the pressure fluid impacts the transfer foil and thelaminate blank that is supported by the transfer foil is wound onto the3D-substrate.

Blanks of the type recited supra can advantageously include layers madefrom metal wood, here for example tropical wood veneers, leather,artificial leather, textiles materials, like e.g. woven or knittedmaterials or fleece material from natural and/or synthetic fibers inaddition to one or plural layers of plastic foils which cause particularglass effects. The blank can have a size that is tailored to the3D-substrate and does not have to fill the entire cross section of theforming tool. The transfer foil is used as a carrier for the substrate.The transfer foil can be made from a highly elastic foil material whichfacilitates the surface increaser through intrinsic stretching which isrequired for adapting and rolling the blank onto the 3D-substrate. Thestretching and other loading of the 3D-Substrate is reduced orsubstantially eliminated. Transfer foils made from polyolefin like e.g.polyethylene, thus in particular LDPE or polypropylene with a layerthickness of approximately 80-500 μm or transfer foils made fromthermoplastic polyurethanes, PTU, thus e.g. the DESMOPAN® foilds foilsby BAYER Material Science are well suited and are being advantageouslyused. After completion a transfer foil of this type can be removed fromthe coated product or it can remain on the surface of the laminate as anadditional surface protection that can be removed later on. The blank issupported at the transfer foil typically using a contact glue which canbe removed without residue from the visible side of the layer material.Suitable contact glues are well known and commercially available. A goodadhesion between the blank and the transfer foil transfers thestretching of the transfer foil when applied to the 3D-substrate atleast partially to the blank and thus prevents a formation of wrinkleswhen molded to the 3D-substrate.

A particularity of the device according to the inventions that at leastone retraction space for at least one displaceable heat radiatorarrangement is formed at the tool trough wherein the heat radiatorarrangement includes activatable upward radiating heat radiators andactivable downward radiating heat radiators; and in order to heat thelayer material the heat radiator arrangement

in the pressure bell closing position and after setting the pressuremedium pressure at or below 30 kPa within the tool trough interior

is displaceable from its retraction cavity into the intermediary spacebetween the laminate and the 3D-substrate; and

using the activated upward radiating heat radiators the layer materialis heated in a controlled manner and glue that is arranged at thelaminate contact side is activated; and

Using the activated downward radiating heat radiators the surface of the3D-substrate is heated; and

after completion of the heat treatment the heat radiator arrangement isreturnable into its retraction cavity.

In an advantageous embodiment of the device according to the inventionit is advantageously provided that a respective box is applied at twoopposite side walls of the tool trough, wherein the box defines a returncavity that is open towards an interior of the trough for a displaceable “half” heat radiator arrangement, and

the “half” heat radiator arrangement after insertion into the troughinterior form the heat radiator arrangement.

A “half” radiator arrangement requires a smaller retraction cavity whichcan be implemented with a smaller configuration. The “half” heatradiator arrangement can be moved from the adapted retraction cavityinto the interior of the trough more quickly.

A radiation in upward direction and a radiation in downward directionrespectively occur vertically. Consequently it is advantageouslyprovided when the activate able upward radiating heat radiators and theactivate able downward radiating heat radiators are arranged at ahorizontally or substantially horizontally oriented heat radiatorarrangement is move able from at least one retraction cavity that isarranged at the tool trough and oriented horizontally or substantiallyhorizontally into the intermediary space between the laminate and thesubstrate to be coated. When a respective box is applied to two oppositeside walls of the tool trough herein the box defines a respectiveretraction cavity that is open towards the trough interior for a moveable “half” heat radiator arrangement. Each box and each return cavityand each “half” heat radiator arrangement is oriented horizontally orsubstantially horizontally. In this context “oriented substantiallyhorizontally designates an orienting that deviates by less than 12° fromthe horizontal orientation.

According to another advantageous embodiment advantageously IR surfaceradiators are used as heat radiators whose heat element is made fromplural strips made from a temperature resistant metal foil that arearranged parallel adjacent to each other and which form a continuousconductor, wherein the metal foils are caused to glow when currentpasses through and then the metal foil reaches a temperature e ofapproximately 800° C., wherein medium wave to long wave IR radiation ina wave length range of 2.6 to 9.6 μm is emitted.

Using an electronic control a smaller wave length range can be selectedfrom the entire wave length range and a heating to a particulartemperature e range can be set in the irradiated material. Aparticularity of these IR surface radiators with heating foil is therehigh radiation intensity of up to 50 kilowatt per square meter and theirvery quick response properties. After switching on the nominal power isalready reached within a 8-10 seconds and an operating temperature e ofapproximately 800° C. is reached after switch off the temperature edrops within 5 seconds from 800° C. is less than 200° C. Mini infra-redradiators of this type are already available with dimensions ofapproximately 120 mm×120 mm from which the desired radiator surface canbe put together in modules. Each individual mini infra-red radiator isconfigured with a pyrometer which facilities detecting the temperature eof the irradiated material and which facilitates controlling thetemperature e in the irradiated portion of the material by adaptedcontrolling of the radiator. This way a regional temperature edistribution at the irradiated material can be implemented. IR surfaceradiators of this type are sold for example KRELUS AG, 5042 Hirstall,Switzerland.

In order to activate UV hardening glues UV-LED systems areadvantageously used which facilitate quick turn on and turn off andwhich provide a high irradiation power with little installation spacerequirement. Suitable UV-LED systems are distributed for example byHERAEUS Noblelight GmbH, 63450, Hanau, DE. UV LED systems of this typecan be integrated for example into the heat radiator arrangementaccording to the invention.

An important criterion of the instant forming tools is their formingsurface which defines a maximum linear dimension of a 3D-substrate whichcan be coated in a forming tool. The forming surface is defined by thesurface of the lower able table. Rectangular table surfaces arepreferred that have a dimension of 400 mm×200 mm—approximately 1000 mm×500. The objects can be coated that have a maximum linear dimensionthus in particular length of approximately 36 cm—approximately 96 cm. Informing surfaces of less than 800 cm2 the cost for the forming tool doesnot correspond to the value of the goods to be coated. For formingsurfaces greater than 5000 cm2 the cost for the high pressure suitableconfiguration increases considerably. Table surfaces of approximately540 mm×approximately 360 mm—approximately 800 mm×600 mm are furtherpreferred. In forming tools of this type the 3D-substrates that are thetypical for theses substrates can be coated. On a table surface of 540mm×360 mm typically one piece laminate with dimensions up to 580 mm and380 mm can be processed.

According to another advantageous embodiment the device according to theinvention can be provided with the laminate or with a transfer foil witha laminate blank automatically. For this purpose a transport arrangementis provided which is subsequently described only for feeding one piecelaminate or laminate pieces. This transport arrangement is configuredwith:

a magazine that includes a supply of laminate pieces;

a transport frame that is movable over the magazine wherein thetransport frame lifts and retains the uppermost laminate piece with asuction force;

the transport frame that supports the laminate piece is movable belowthe pressure bell in its uppermost dead center and applicable at thislocation to the circumferential seal surface of the pressure bell; andwhen lowering the pressure bell the transport frame contacting thepressure bell continues to support the laminate piece.

Advantageously also the 3D-substrate to be coated can be automaticallyfed. For this purpose a transport path for the 3D-substrate to be coatedis provided:

with a rail that is fixed at the tool trough and provided with a lineararrangements wherein at least one sled is move able along the railwherein the sled transports transport plates from an application stationto a retaining station and transport plates from a retaining station toa retrieval station;

in the placement station a carrier plate is applicable to the transportplate arranged at this location wherein the carrier plate supports a3D-Substrate to be coated or plural 3D-substrates to be coated;

lifting and pivot arms mounted at movable slides transport the carrierplate that is arranged in the retaining station and retains one orplural 3D-substrate to be coated from the retaining station in aposition below the lifted pressure bell; and

place the 3D-substrate within a cut out at an intermediary frameattached at the tool trough on a table top of the table that is in itsupper dead center; and

the coated product is retrieved in the retrieval station.

Using the transport arrangement of this type and/or the transport paththe cycle time for coating a 3D-substrate can be reduced considerably.

It is advantageous when the carrier plate recited supra

is made from a stable and durable plastic material;

coated with a release agent like e.g. TEFLON®;

has a polygonal, in particular rectangular surface; and

magnetically responsive material, like soft iron is provided in cornerportions of the polygonal surface.

For transporting the carrier plate supporting one or plural3D-substrates to be coated from the retaining position into a positionbelow the raised pressure bell lifting and pivot arms are advantageouslyprovided wherein an activate able electro magnet is attached at a freeend of the lifting and pivot arms wherein the activate ableelectromagnet can contact a corner portion of the carrier plate and thecarrier plate is lifted by activating the electro magnets. A simple andoperationally reliable arrangement for handling and transporting thecarrier plate is provided.

According to another advantageous embodiment of the device according tothe invention it is provided that the pressure bell is arrest able orinterlock able in its lower dead center by motor driven adjust ablelocking bolts that are arranged at the pressure bell wherein the frameis fixed at the tool trough and made from a massive steel plate. Anarrangement of this type takes load off the elbow arrangement which thendoes not have to deliver any drive power in the closed position of thepressure bell.

According to another advantageous embodiment according to the inventiona double elbow arrangement is provided for lifting the pressure bellfrom its lower dead center to its upper dead center which has two elbowlevers respectively provided with a separate drive; and by blocking oneelbow lever and activating the other elbow lever the pressure bell canbe pivoted into a service position in which the circumferential sealsurface of the pressure bell is essentially vertically oriented. In thisservice position the pressure bell interior as well as the tool troughinterior is easily accessible to perform cleaning, repair and servicework.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is subsequently described based on advantageous embodimentwith reference to drawing figures:

FIG. 1A illustrates a perspective view of a 3 D-substrate functioning asa demonstration object;

FIG. 1B illustrates a sectional view along the sectional line II-II ofFIG. 1A;

FIG. 2 illustrates the essential elements of an arrangement for coatinga 3D-substrate with a laminate in a schematic perspective view;

FIG. 3 illustrates the representation according to FIG. 2 withadditional reference numerals; the transport frame 128 is arranged abovethe magazine 122;

FIG. 4 illustrates a representation that is modified over FIG. 2; thetransport frame 128 with the attached laminate piece 10 is arrangedbelow the pressure bell 50;

FIG. 5 illustrates a representation that is modified over FIG. 2; the3D-substrate to be coated is in a position below the raised pressurebell 50;

FIG. 6 illustrates a perspective virtual sectional view; a front sidewall of the tool trough 60 is removed which facilitates a view into theinterior of the trough 65; the pressure bell 50 is lowered and alaminate piece 10 is clamped between the pressure bell 50 and the tooltrough 60;

FIG. 7 illustrates a detail of a virtual side view, the table 80 is inits upper dead center within the tool trough and a carrier plate 168, isarranged on the table top 82 wherein the carrier plate retains the3D-Substrate 3 to be coated;

FIG. 8 illustrates a modified representation according to FIG. 7;lowering the table 80 has commenced;

FIG. 9 illustrates a modified illustration according to FIG. 7; thetable 80 is in its lower dead center;

FIG. 10 illustrates a schematic virtual top view of a face of thedevice; each “half” heat radiator 102, 104 is in its retraction cavity67′ or 67″;

FIG. 11 illustrates a modified representation according to FIG. 10 ; thetwo “half” heat radiator arrangements 102, 104 are moved into the troughinterior 65 and form the heat radiator arrangements 100 into theintermediary space 90 between the laminate piece 10 and the 3D-substratethat is to be coated.

FIG. 12 illustrates modified representation according to FIG. 11;additional activatable UV radiators 119 are arranged at a top side ofthe heat radiator arrangement 100;

FIG. 13 illustrates modified representation according to FIG. 11;additional heat radiators 59 are arranged at an inside of the sealingwall 54 of the pressure bell 50;

FIG. 14 illustrate a modified representation according to FIG. 6; thetable 80 is in its upper dead center and the laminate piece 10 isstretched over the 3D-ubstrate 3 like a tent;

FIG. 15 illustrates a modified representation according to FIG. 13; thepressure bell 50 is raised and the coated 3D-Substrate 3 sits on itscarrier plate 168, which is arranged within a cut out 72 at theintermediary frame 70 at the tool trough 60; an blown up detail viewshows the coated product 9;

FIG. 16 illustrates a modified representation according to FIG. 5, whichillustrates the transportation of the coated products 9 out of theforming tool 20;

FIG. 17-FIG. 21: illustrate FIGS. 17-21 from the reference articlerelating to the TOM-process;

FIG 22 and FIG. 23: illustrate modified representations according toFIG. 16, which show the transportation of the coated 3D-substrate 3 outof the forming tool 20 through the retaining station 163 into theretrieval station 165;

FIGS. 24 through 28 Illustrate modified representations according toFIG. 5, which illustrate different positions of a double elbow leverarrangement 130 and the arrangements of the pressure bell 50 thusgenerated; and

FIG. 29 illustrates a modified representation according to FIG. 28,which shows a view of the pressure bell 50 in its service position.

DETAILED DESCRIPTION OF THE INVENTION

Candidates for the 3D-substrate are objects which have a three dimensiondeveloping surface or shell whose surface shall be coated with apermanently adhere in laminate. Typically the enveloping surface orshell is supported at a support structure which subsequently alsoprovides the arrangement and attachment of the coated product at thearea of end use. Substrates or carrier elements of this type can be madefrom metal, for example a light metal like aluminum, magnesium and theiralloys, from a plastic material thus e.g. from a thermos plasticsynthetic material that can be process through injection molding likepolyamide (PA), Acrylnitril-Butadien-Styrol-Terpolymer (ABS),Acrylester-Styrol-Acrylnitril-Terpolymer (ASA), Polyoxymethylene (POM),Polyvinylchloride (PVC) or Polyarylene-sulfon (PSU). Furthermore it canbe made from wood and other stable and durable materials. Forapplications as interior furnishing in motor vehicles, 3D-substrates ofthis type including their support structure are typically produced asone piece injection molded components and are typically made fromplastic materials like e.g. PA, ABS, ASA, POM, PVC or PSU.

The plastic material selected for coating is typically selected withrespect to formability with a fluid pressure medium, in particularcompressed air at a pressure medium pressure of 2-18 bar with respect todurability, its protective function, reliability and in particular withrespect to obtainable decorative effects. One layer or multi-layerlaminates can be used. The decorative effects can originate from thesurface of the 3D-Substrate and can be modified by one or pluraltransparent foil layers. Alternatively the decorative effect can becaused by a layer made from a multi-layer laminate or composite materialwhich is modified or reinforced by one or plural transparent foillayers. For example the decorative effect can be caused by a metal foilor a tropical wood veneer or a plastic veneer imitation and thedecorative effect can be modified and reinforced by transparent foils,also in order to achieve particular gloss effects, for example to obtaina piano lacquer appearance by using foil as discussed in the document DE10 2007 054 579 A1. Furthermore multi layer laminates can include atleast partially imprinted metalized and/or otherwise coated foil layerswhich is known from the IMD method. Metalized foil layers shall alsoinclude foils that are provided with conductive paths, for example withconductive paths that are formed from imprinted silver paste or withconductive paths made from metal foils.

According to the invention the one layer or multi-layer laminates can beused that are known from the document DE 199 57 850 A1. When the layermaterials include one layer or multi-layer foil arrangements thethermoplastic or durable plastic foil materials can be used that arecold stretchable and that are known form the document EP 0371 425 B1.These are for example: poly carbonates, for example the MACROLON® typessold by BAYER AG, polyesters, thus in particular aromatic polyesters,e.g. polyalkylenterephthlate, polyalkylennaphthenate, polyamides (e.g.PA6 or PA66 types high strength Aramide®-Foils; furthermore olyimidesfor example CAPTON® are foils based on poly diphenyloxid-pyromellitimid,polyarylate, which have proven well suited for this purpose.

Furthermore the foils that are known from the document EP 0 691 201 B1and which are 0.02 mm-0.8 mm thick and which are made from thermoplasticsynthetic material can be used together with a paint layer that is 3μm-50 μm thick. As suitable foil materials thermoplastic aromaticpolycarbonates thermoplastic Polyarylsulfone, thermoplastic Celluloseesters, thermoplastic Polyvinylchlorides and thermoplasticStyrol-Acrylnitril-Copolymerisates are recited. The paint layertypically includes pigments which are dispersed in a particular paintlayer carrier that is based on Polycarbonate. All materials and materialcombination recited here in can also be used according to the instantinvention.

Furthermore the laminate can consist of a structured foil by itself or amulti-layer laminate can be used whose visible layer and cover layer aremade from a structured foil. Structured foils have a structured surfacewhich is formed from protrusions and recesses relative to a flat nominalsurface. Structures of this type can imitate a natural original forexample a leather grain of natural leather or a wood grain at a woodsurface. Using respective contour data the surface of an embossingroller or the tool surface of a positive or negative tool can beprocessed accordingly. Furthermore synthetic structures can be generatedaccording to predetermined CAD data. Through molding or embossing thestructure of the embossing roller or of the embossing tool surface istransferred to the surface of a plastic foil. Details for producing theaccordingly structured press tool surfaces can be derived for examplefrom the document DE 198 55 962 C5 and the literature recited therein. Astructure foil according to this embodiment is sold by EXCEL GmbH, 83101Rohrdorf, DE and the trade name PMU 6040 UV. This foil is made from ablend of thermoplastic polyurethane and poly methacrylate and has anundulation of 3 mm at the most. This structure foil can be obtained andused transparent or colored, for example also colored solid black.

Additional suitable layer materials are provided in the documents DE 10327 435 A1, DE 2006 031 315 A1 and DE 199 57 850 A1.

Laminates of this type are well suited for performing the coatingaccording to the invention wherein the layer materials include plasticfoils with a layer thickness of 20-1000 μm, in particular of a layerthickness of 50-500 μm.

According to another advantageous embodiment of the method according tothe invention a laminate blank that is tailored to the 3D-substrate isplaced on a transfer foil. Only the transfer foil is clamped between thetwo sealing surfaces of the pressure bell and the tool trough so thatthe two tool interior spaces are separated from each other pressuretight. Hen loaded with the fluid pressure medium at a pressure mediumpressure of 2 to 18 bar the pressure fluid impacts the transfer foil andthe laminate blank supported by the transfer foil is wound onto the3D-Substrate. Blanks of this type can advantageously include layers madefrom metal, wood in particular tropical wood veneer, leather, syntheticleather, textile materials, like e.g. woven and knitted material orfleece material made from natural fibers and/or synthetic fibers andsimilar. In addition to one or plural layers of plastic foils whichcause particular decorative effects. The blank can have a size that istailored to the 3D-Substrate and does not have to fill the entire crosssection of the pressure bell. An undesirable deposition of layermaterial on the tool elements can be limited. The transfer foil is usedas a carrier for the laminate. The transfer foil can be made from ahighly elastic foil material which provides surface increase throughintrinsic stretching which is required for winding the blank onto the3D-substrate. Stretching or other loading of the blank is reduced orsubstantially eliminated. Transfer foils made from Polyolefin, like e.g.Polyethylene, thus in particular or LDPE, or Polypropylene, respectivelywith layer thicknesses of 80-500 μm or transfer foils made fromthermoplastic Polyurethanes, PTU (thus for example DESMOPAN® foils byBayer Material Science are well suited and are typically used. Aftercompletion the transfer foil can be removed from the coated product orcan remain as an additional surface protection on the surface of thelaminate. The blank is held at the transfer foil typically by a contactglue which can be removed without any residue from the visible side ofthe laminate. Suitable contact glues are well known and commerciallyavailable. A good adhesion of the blank at the transfer foil transfers aportion of the stretching of the transfer foil that occurs duringtransfer foil forming, to the blank and thus prevents an undesirablewrinkle formation of the blank.

In the product that is produced according to the invention the laminateis connected through a glue layer with the 3D-Substrate. A glue layer ofthis type facilitates using laminates with a high reset force, formingthe laminate in small curvature radii and a safe and reliable attachmentof the laminate edges at the 3D-Substrate, in particular also at it'sunder cuts.

Glue systems and glue compounds for generating a glue joint of this typeare well known to a person skilled in the art who can choose from manycommercially available suitable products. A method is preferred where aone component glue compound is applied in advance only on the contactside of the laminate. Furthermore only the glue layer that is arrangedon the contact side of the laminate shall be provided in a non-activatedcondition which facilitates storage and handling. Through controlledactivation treatment the initially inactive glue layer shall betransferred into an active condition in which the gluing process is thenimitated thereafter. And advantageous activation treatment is heatingthe glue compound to its activation temperature e. In this casethermally activate able glue compounds or hot melt glues are being used.Irradiating with actinic radiation, thus in particular UV radiation isan alternative or additional activation treatment. In this case UVhardening glues are being used.

The application can be performed in that a solution of an activate ableglue compound is applied to the contact side of the laminate by silkscreening. Thereafter the solvent is removed by evaporation and drying.A thin even dry layer made from glue compound can be obtained which istypically only applied in places where gluing force is required.Alternatively an activate able glue compound of this type can bedirectly removed from a silicon coated release paper and transferred forexample in that layer material and release paper provided with theactivate able glue compound is run through a calendar roller gaptogether. Furthermore accordingly selected powdery glues can be appliedby extrusion coating, for example by hot extrusion or powder coating orby other direct coating. Various thermally activate able melt glues arealso obtainable in the form of melt glue foils or fleeces and can beapplied in this form for example also in an accordingly cut blank ontothe contact side of the layer material.

Thermally activatable glue compounds of this type, melt glue and notmelt glues are known to the person skilled in the art who can choosefrom many commercially available products. Subsequently only a fewexemplary recipes are recited.

A thermally activatable glue compound can include an elastomeric basepolymer and a modification resin, wherein the modification resinincludes a glue resin and/or a reactive resin. The elastomeric basepolymer can be a thermoplastic polyurethane or a mix from powderypolyurethane components like aromatic diisocyanates and polyesterpolyoles with a high content of end hydroxol groups. Thermoplasticpolyurethanes with a high content of end Hydro-xyl groups provide aparticularly high gluing strength at various substrates.

An alternative, thermally activatable glue compound can include

50 to 95% by weight of a gluable Polymer, and

5-50% by weight of an Epoxy resin or of a mix of plural Epoxy resins;wherein the gluable polymer in turn includes acrylic acid compoundsand/or methacrylic acid compounds and/or one or plural co-polymerizablevinyl monomers.

Another thermally activate able glue compound can include:

40 to 98% by weight of block polymer including acrylic,

2-50% by weight of one or plural techifying epoxy resins and/or Novolakresins and/or Phenolic resins; and

0-10% by weight hardener for cross linking the epoxy resins and/or theNovolak resins and/or the Phenolic resins.

For optimum cross linking suitable initiators and/or cross linkers canbe added to the glue compounds, for example IR radiation absorbing photoinitiators and/or UV light absorbing photo initiators. Additionally socalled primers can be provided. Suitable primers are for example hotseal glues based on polymers like ethyl vinyl acetate or functionalizedethylvinylacetates or also reactive polymers.

Thermally activatable glue compounds of this type can be produced andadjusted so that they have an activation temperature in a range of60-140° C., Further advantageously an activation temperature of 75-130°C. activation temperatures of this type can also be reached quickly andeasily by heating in a forming tool. After cooling below this activationtemperature a sufficient initial glue strength is quickly obtainedbetween the layered material and the 3D-Substrate so that the contactpressure can be terminated quickly and the product can be removed fromthe tool.

The heated laminate is pressed and formed by fluid pressure medium, inparticular compressed air under a pressure medium pressure of 2-18 barfor a sufficient time period to the 3D-Substrate that is also heatedwherein the pressing and forming is performed for example for 2 to 30seconds. When the fluid pressure medium is subsequently removed from thepressure bell quickly the associated layering of the temperature of thetool and the laminated 3D-substrate facilitates a quick cooling of theglue layer below its activation temperature.

Further details regarding thermally activate able glue compounds can bederived from the document DE 10 2006 042 816 A1. The thermally activateable glue compounds described there in are advantageously used accordingto the instant invention. Thus thermally activate able glue compounds,melt glues and of melt-glue are particular advantageous which can bebrought to their activation temperature within seconds and which providea sufficient initial glue strength within seconds of cooling timestowards the contact surface of the laminate and to the 3D-Substratesurface. Particularly well suited are the heat activate able gluecompounds and melt glues that are sold by Bayer Material Science underthe tradename DESMOMELT®. These are mixes of crystalline Polyester-polyoles and crystalline Diisocanate which form polyurethanes withindependent Hydroyl groups upon heat activation. This obtains goodadhesion at the many materials like for example on leather, textiles,wood fiber materials and numerous synthetic materials including PURelastomers and soft PVC. The different DESMOMELT® types can be processedfor example as a solution in select solvents, e.g. butanone-2, acetoneor methylethylketone as melt glue foils or directly as a powder bydirect coating. The minimum activation temperature is approximately 60°C. When loaded with the high pressure fluid a sufficient initialstrength is already obtained within seconds. Wherein the strengthincreases even more within hours after removal of the coated productfrom the forming tool.

The laminate that is provided with a partial or full surface dry layerfrom thermally activate able glue compound or melt glue has to be heatedbefore forming far enough so that the glue compound or the melt glue isactivated. This is performed by heating the layer material to theactivation temperature of the thermally activate able glue compound orof the melt glue or beyond the activation temperature. Typically anactivation to an activation temperature in a range of 60° C. to 140° C.,in particular and activation temperature of 75-130° C. is provided.

Also the plastic foils included in the one layer or multi-layer laminatehave to be heated in order to facilitate their precise molding at the3D-Substrate. Thus, a maximum heating to the forming temperature knownfrom thermo forming can be provided; c.f. “Thermoformen in der Praxis”,by Peter Schwarzmann, Second edition, Carl Hanser Verlag, Munchen 2008,page 40. Typically a heating to lower temperatures is sufficient becausea higher pressure medium pressure is provided with the pressure mediumpressure of the fluid pressure medium of up to 18 bar, compared tocompressed air forming and thermos forming conditions. In some cases aheating to temperatures below the glass transition temperature T_(g) ofthe respective foil material can be sufficient.

The heating described supra is performed according to the invention inan interior of the tool trough of the forming tool. A heat radiatorarrangement is inserted into the intermediary space between the laminatethat is clamped between the pressure bell and the tool trough and the3D-substrate arranged on the lowered table. Wherein the heat radiatorarrangement has activate able upward radiating heat radiators andactivate able downward radiating heat radiators. The upward radiatingheat radiators heat the laminate in a controlled manner and activate theglue that is arranged at the contact side of the laminate in acontrolled manner. In case of UV hardening glues a top side of the heatradiator arrangement can include alternatively or additionally activateable upward radiating UV radiators, thus in particular UV LEDV systems.The downward radiating heat radiators heat surface of the 3D-Substratein a controlled manner. In any direction only small distances of less200 mm, advantageously less than 100 mm have to be covered. The shortdistances provide high radiation intensity using the heat radiators thatare arranged in an optimum manner facilitates a very quick heating.Furthermore using the heat radiators with a quick response time like theIR surface radiators described supra which include a metal foil that iscaused to glow as a heat element facilitate very quick heating.Typically an activation of the heat radiators for a duration of lessthan 60 sec, advantageously less than 30 seconds is completelysufficient. Using UV-radiators thus, in particular UV-LED-Systems thatcan be turned on and off quickly facilitates reaching a sufficientcuring of the UV-curing glue compounds within a few seconds. Thus shortcycle times of less than 120 sec. can be implemented.

At the point in time of the heat treatment an initial air pressure inthe interior of the tool trough and in the interior of the pressure bellis lowered to a value of less than 30 kPa corresponding to thesurrounding atmospheric pressure to a value of at least than at least 30kPa. Further advantageously an evacuation to a pressure of less or equalto 20 kPa is performed. If technically feasible the pressure can bereduced to a value that is even lower. This pressure reduction has to beperformed for each individual coating cycle within the cycle time. Aquick lowering of the pressure can be facilitated in that a respectiveflow connection of tool trough interior and pressure bell interior witha previously evacuated vacuum container of sufficient size is provided.The vacuum container can be evacuated again during the phase whenatmospheric pressure is provided again in both interior spaces after aventilation.

During the method according to the invention the forming of the laminateand contact with the 3D-substrate is performed through gradual andincremental positive forming. After completing the heat treatmentaccording to the invention and retracting the heat radiator arrangementsinto their respective retraction spaces the table is raised into itsupper dead center, wherein the 3D-substrate penetrates the layermaterial plane and takes the laminate along like a tent. In the interiorof the tool trough and in the interior of the pressure bell the reducedpressure medium pressure of less or equal 30 kPa is still provided.After the table has reached its top dead center a fluid pressure mediumadvantageously compressed air is introduced into the pressure bellinterior at a pressure medium pressure of 2-18 bar, advantageously at apressure medium pressure of 3-15 bar. These pressure medium values areabsolute values. A pressure medium pressure of 2 bar is therefore higherby one bar than the ambient atmospheric pressure. A pressure mediumpressure of less than 2 bar does not provide sufficient contact pressureto apply the in particular multi-layer laminate to fine details of the3D-Substrate so that such details are reliably reproduced after coating.A pressure medium pressure of greater than 18 bar does not provide muchbetter results, however requires a significantly increased configurativecomplexity to control the high forces that impact the pressure bell, inparticular when the table surface significantly exceeds dimension of 500mm×1000 mm.

Loading with the high pressure medium pressure of 2-18 bar presses thelaminate that is clamped between the pressure bell and the edge of thetool trough against the 3D-Substrate. Additional laminate residuals aredeposited on the carrier plate supporting the 3D-Substrate and anintermediary frame which forms an upper termination of the tool trough.The surfaces of the tool trough are advantageously coated with a releaseagent like e.g. TEFLON® which facilities a subsequent removal ofresiduals of the laminate. This loading with the high pressure mediumpressure of two—18 bar is continued for several seconds for example for2-30 seconds in order to obtain a sufficient adhesion and strength ofthe glue connection between the 3D-Substrate surface and the moldedlaminate. Thereafter the tool trough interior space is ventilated, thepressure bell interior is also ventilated and the pressure bell israised. The carrier plate supporting the coating 3D-Substrate contactsthe table top of the raised table however is now arranged in a cut outwithin the intermediary frame and is provided at this location for anaccess of a conveying device which moves the carrier plate with thecoated 3D-Substrate out of the forming tool. Further details can bederived from the subsequent description of a device according to theinvention.

FIG. 1A illustrates an exemplary 3D-Substrate 3 in a slanted viewwherein the 3D-Substrate is also shown in subsequent figures. FIG. 1Bshows the 3D-substrate 3 in a sectional view along the sectional lineII-II of FIG. 1A. This 3D-substrate 3 is an oval element with roundedcorners and edges. The entire element is made from white Polyamide andhas a length of 180 mm, a width of 100 mm, a height of 40 mm and a layerthickness of 5 mm. The top side 4 includes a concave cavity 5 with adepth of approximately 8 mm. This top side 4 transitions in a roundedform into a circumferential bar 6 in which a circumferential groove 7 isrecessed. It shall also be illustrated that the face of the bar 6 can bereliably coated with a permanently adhering laminate and so that evenunder cuts are reliably coated, thus the grooves 7 is lined and thelower edge 8 of the bar 6 is enveloped.

A forming tool configured to perform the method according to theinvention is subsequently described with reference to FIGS. 2-5. ThusFIG. 2 illustrates an over view of the forming tool with its essentialcomponents and its peripheral arrangements, namely a transportarrangement for introducing pieces of laminate into the forming tool anda transport path for feeding the 3D-Substrate 3 that is to be coated.The detailed slanted images 3, 4 and 5 show different stages of themethod. FIGS. 6, 13 and 14 illustrate virtual sectional views in slantedimages where a longitudinal front side that is in front in top view isremoved in order to provide a view into an interior of the forming tool,e.g. to describe an adjustment of a table within a tool trough. FIGS.10, 11 and 12 illustrate virtual sectional views in schematic side viewswhere a lateral face that is in front in top view is removed in order todescribe the arrangement and adjustment of a heat radiator arrangementwithin the tool trough.

As illustrated in FIG. 2 the forming tool 20 forms an essentiallyrectangular device with a column frame 30 whose columns 34 are supportedon a rectangular base plate 32. The shorter rectangular side 22 definesthe direction of a face or face wall of the forming tool 20. The longerrectangular side 24 defines the direction of a side wall of the formingtool 20. Along the columns 34 an upper tool half, namely a pressure bell50 is supported so that it can be raised and lowered. The lower toolhalf is formed by a tool trough 60 that is arranged on the base plate 32in a stationary manner, wherein a table that can be raised and loweredis arranged in the tool trough. Furthermore a heat radiator arrangementis arranged in the tool trough 60. The layer material 10 used forcoating the 3D-Substrate 3 is introduced into the forming tool 20 by atransport arrangement 120. The 3D-Substrate 3 that is to be coated isrun out along a transport path 150.

As illustrated in the perspective views of FIGS. 3 and 4 more in detailthe forming tool 20, has a 4 column frame 30 with a base plate 32, withand 4 vertically oriented columns 34, which support a Cover plate 36 onwhich the bearings 38 for a drive shaft 39 of an elbow arrangement 40are mounted. This drive shaft 39 is driven by a non-illustrated gearedmotor. The drive shaft 39 supports 2 offset cranks 1′ and 41″, whichdrive a connecting rod 42 which adjusts an axle 43. The axle 43 issupported in a bearing pair 44 which sits on a support plate 45 that ismove ably supported at the columns 34. An upper tool half is attached atthe bottom side of the support plate 45, namely the pressure bell 50.Therefore actuating the elbow lever arrangement 40 moves the pressurebell 50 up and down within the 4 column frame 30. The Pressure bell 50essentially forms a downward open box which has 2 opposite side walls51′ and 51″, to opposite side walls 53′ and 53″ and a ceil wall 54 whichjointly define a pressure bell interior 55. At the face wall 51′ tooffset motor adjustable locking bolts 52′ and 52″ are arrange which aremove able away from the face wall 51. At the face wall 51″ two offsetmotor adjustable locking bolts 56′ and 56″ are arranged that are moveable away from the face wall 51″. The lower circumferential edge of thepressure bell 50 forms a circumferential seal surface 58 which can beprovided with an additional circumferential seal.

FIGS. 24-29 illustrate an alternative adjustment arrangement for thepressure bell 50. Here in a double elbow arrangement 130 is providedbetween the cover plate 36 of the 4 column frame 30 and the cover plate54 of the pressure bell 50 wherein the double elbow arrangement 130 hastwo identical simple elbow arrangements 131 and 133 that arerespectively configure with a separate drive 134 out of whichsubsequently only the elbow arrangement 133 is described. A main shaft136 is supported at 2 off set bearing blocks 135′ and 135″ wherein themain shaft is drive able forward and backward by the geared motor 134.The forward drive raises the pressure bell 50 and the reverse drivelowers the pressure bell 50. Alternatively the lowering of the pressurebell 50 can also be caused by its weight and the transmission motor 134only performs a breaking function during lowering. This facilitatesenergy efficiency when operating the double elbow arrangement 130. Twooffset cranks 137′ and 137″ sit on the main shaft 136 wherein the cranksupport an upper axle 138. At this upper axle 138 two pivoted controlarms 139′ and 139″ are arranged which support a lower axis 140 which isrotate ably supported at 2 offset bearing blocks 142′ and 142″ which arein turn fixed on the cover plate 54 of the pressure bell 50.

In the representation according to FIG. 24 the pressure bell 50 is intis top dead center and the two cranks 137′and 137″ extends verticallyupward. However also an arrangement could be provided in which the twocranks 137′ and 137″ move the pressure bell 50 by approximately 5°beyond this upper dead center to a stop. A crash safety is providedwithout a use of motor power. By synchronous and symmetrical activationof the 2 transmission motors 132 and 134 the two cranks 137′ and 137″are adjusted through an intermediary position c.f. FIG. 25 into avertically downward orientation and the pressure bell 40 goes into itslower dead center, c.f. FIG. 26. Furthermore an operating mode ispossible in which only an elbow lever arrangement 133 is adjusted andthe other elbow arrangement 131 remains locked. This adjusts thepressure bell 50 through an intermediary position, c.f. FIG. 27 into aservice position illustrated in FIG. 28. In which the ceiling wall andthe circumferential seal surface 58 of the pressure bell 50 aresubstantially vertically oriented. FIG. 29 shows a direct view of thisservice position. In this position the interior space 55 of the pressurebell 50 and the interior space 65 of the tool trough 60 are accessiblefor service.

The double elbow arrangement 130 achieves the following advantages:

the bell weight is distributed over plural sliding bushings which canthus be configured smaller;

no support plate is required at the column frame;

transversal forces into the column frame and possible wedging areavoided;

the bell width can be used for a lowering movement;

the two motors only have to perform a break function during the loweringmovement;

the upper dead center and the lower dead center of the pressure bell canbe arrested;

due to this arresting the positions can be maintained without enginepower; and

eventually the pressure bell can assume a service position in which thepressure bell interior and the tool trough interior space are accessiblefor service.

Within a four column frame 30 a lower tool half namely a toll trough 60is arranged on the base plate 32 wherein the tool trough 60 has anessentially rectangular cross section and is made from 20-30 mm steelplates that are welded together. The tool trough 60 has opposite sidewalls 61′ and 61″, opposite face walls 63′ and 63″ and a base wall 64,which jointly define a trough interior 65. The upper termination of thetool trough is formed by an intermediary frame 70, which is connectedwith the tool trough 60 in a heat conducting manner. The tool trough 60forms a heat sink for the intermediary frame 70. The intermediary frame70 has a polished contact surface for an edge of the laminate. Whenrequired the contact surface can be coated with a release agent likee.g., TEFLON® or similar. The intermediary from 70 envelops a closed cutout 72.

As evident in particular from the sectional top views according to FIGS.10, 11 and 12 recesses 62′ and 62″ are cut out at the two side walls61′and 61″ and adjacent to the recesses 62′ and 62″ a box 66′ and 66″ isapplied and welded down at each side wall 61′ and 61″. The box 66′defines a retraction cavity 67′ and the box 66″ defines a retractioncavity 67″ each retraction cavity 67′ and 67″ is open towards the troughinterior 65. In each retraction cavity 67′ and 67″ a “half” heatradiator arrangement can be arranged as described infra. Each box 66′and 66″ illustrated in FIGS. 10, 11 and 12 is horizontally oriented andrespectively defines a horizontal retraction cavity 67′and 67″.

As illustrated in the sectional perspective view of FIG. 6 and in thesectional detail views according to FIGS. 7, 8 and 9 a table 80 isarranged within the tool trough 60 which lowers a table 80, whichincludes a table top 82 and which can be lowered and raised by a liftingarrangement . This lifting arrangements includes 2 offset and paralleloriented respectively motor driven shafts 85′and 85″, which are run in asealed manner through the front side wall 61′ of the tool trough 60 andcorresponding two offset and parallel oriented respectively motor drivenshafts 87′and 87″, which are run respectively in a sealed manner throughthe opposite rear side wall 61″ of the tool trough 60. Each shaft 85′,85″, 87′ and 87″ respectively pivots a crank arm 88, at whose free end arespective connection shaft 89 is rotate ably supported. At the bottomside of the table top 82 two support rails 83′ and 83″ are arranged thatextend in the longitudinal direction parallel to longitudinal edges ofthe table top 82. Two sliding pieces 84 are move ably supported in eachsupport rail 83′and 83″. A connection shaft 89 rotate ably engages eachslide piece 84. A motor induced pivoting of the crank arms 88 forces theslide pieces 84 through the connection shafts 89 to slide within thesupport rails 83′, 83″ and the table 80 that is connected with the slidepieces 83′ and 83″ is raised or lowered within its table support.

The schematic detail top view according to FIG. 7 shows a condition inwhich the table 80 assumes its upper top dead center. All four crankarms 88 are pivoted upward and assume a vertical orientation. The loadimpacting the table is reacted by the four vertically oriented crankarms 88 onto the shafts 85′ and 85″ and 87′ 87″. By pivoting the crankarms 88 the table 80 is lowered from its upper dead center c.f. FIG. 8.When the crank arms 88 assume a downward pivoted vertical orientationthen the table 80 assumes its lower dead center; FIG. 9. Consequentlythe table 80 can be adjusted independently from the pressure bell 50within the stationary tool trough 60.

As evident from FIGS. 3 and 4 a transport arrangement 120 for laminatepieces 10 or for pieces of laminate 10 is provided adjacent to a facewall 63′ of the tool trough 60. A magazine 122, that can include a stockof laminate pieces 10 is illustrated merely as a flat trough andassociated with the transport station 120. The magazine 122 has anelevation adjustable magazine base 123, on which a stack 12 of laminatepieces 10 is placed and arranged parallel to the magazine base 122.Using the laterally adjustable magazine side walls 124 facilitates anadaptation to the instant format of the laminate pieces 10. FIG. 3illustrates a hollow transport frame 128 that is supported between 2adjacent parallel oriented support rails 125′ and 125″ wherein a vacuumis obtainable and maintainable in the hollow transport frame wherein thevacuum generates a suction effect at a bottom side of the transportframe 128 through suction pores. The transport frame 128 is move able bythe magazine or by the flat trough 122. Using the suction effect theupper most laminate piece 10 that is arranged in a magazine 122 ispicked up by suction and applied to a bottom side of the transport frame128. The laminate piece 10 thus individualized is moved by the transportframe 128 below the pressure bell 50 which takes its upper dead centerwithin the 4 column frame 30. Since the transport frame 128 is alignedwith the circumference of the pressure bell 50 the top side of thetransport frame 128 is applied to the circumferential ceiling surface 58of the pressure bell 50 and fixed. When lowering the pressure bell 50the laminate piece 10 that is still retained by the transport frame 128can be transported within the 4 column frame 30 in a direction towardsthe tool trough 60.

As illustrated in FIGS. 3, 4 and 24 a transport path 150 is set up alonga longitudinal side 61′ of the 4 column frame 30, wherein the3D-Substrate 3 that is to be coated can be transported along thetransport path. A rail 152 that is stationary and provided with a lineararrangement extends along the transport path 150, wherein a first slide154 and a second slide 156 is move able back and forth along the rail152. The first slide 152 supports a first transport plate 155 and thesecond slide 154 supports a second transport plate 157. A placementstation 160 (right side of FIG. 4), a retaining station 163 center inFIG. 4 and a retrieval station (left side in FIG. 4) is arranged alongthe transport path 150. In the placement station 160 a carrier plate 168is arranged on the first transport plate 155 wherein a 3D-Substrate 3that is to be coated is attached on the carrier plate. Depending on sizealso plural 3D-Substrates 3 can be arranged on a carrier plate 168 sothat a single coating cycle can coat several 3D-Substrates. The carrierplate 168 is made from a stable durable plastic material and includesmaterial that responds to magnetism in each corner portion.Advantageously the carrier plate 168 is made from TEFLON® or is coatedwith a release agent like e.g. TEFLON® which facilitates releasinglaminate residuals which will deposit on the carrier plate 168 duringcoating. Using the first sled 154 the first transport plate 155 is movedfrom the placement station 160 into the retaining station 163. Anotherfirst transport plate 155′ can then be inserted into the empty placementstation 160 wherein another carrier plate 168′ is placed on the firsttransport 155′ wherein another 3D-Substrate to be coated is attached onthe carrier plate. Depending on the configuration of the forming toolhandling of the transport plates 155, 155′, 157 and of the carrierplates 168 and 168′ can be performed manually or by an automatic device.The arrangement illustrated in FIG. 4 is obtained.

The intermediate frame 70 forms the upper termination of the tool trough60 wherein the intermediary frame envelops a closed recess 72 into whichthe carrier plate 168 that retains the 3D-Substrate can be inserted witha close tolerance. The inserted carrier plate 168 then sits on the tabletop 82 of the table 80 when the table 80 is in its upper dead center. Arespective rail 73′ and 73″ is arranged along the two face walls 61′ and61″ of the tool trough wherein a respective linear arrangement isarranged at each rail and facilitates moving a respective slide 74 or74″ along the rail 73′ or 73″. Two respective offset lifting and pivotarms are arranged at each slide 74′, 74″ which are lift able relative tothe slide 74′, and 74″ and which are pintable from an orientationparallel to the slide 74′, 74″. A respective activate able electromagnet76 is arranged at a free end of each living and pivot arm 75. After theslides 74′, 74″ have been adjusted adjacent to a first transport palletarranged in the retaining station 163 the activated electromagnets 76respectively control and corner portion of the carrier plate 168 andlift the carrier plate 168 by Magnetic force. An adjustment of the twoslides 74′, 74″ transports the raised carrier plate 168 over theIntermediary frame 70, where the Carrier plate 168 is lowered andinserted into the cut out 72. After deactivating the electromagnets 76they can be disengaged from the carrier plate 168 and the lifting andpivot arms 75 can be pivoted into an orientation that is parallel to theslide 74′ or 74″. The carrier plate 168 with the 3D-Substrate 3 that isto be coated then rests on the table top 82 of the table 80 asillustrated in FIG. 5. In a subsequent step the lifting arrangement isactivated and the table 80 is lowered within the tool trough 60 into itslower dead center.

As illustrated in FIGS. 4 and 5 the pressure bell 50 is in its top deadcenter and the transport frame 122 that retains a laminate piece 10contacts the seal surface 58 of the pressure bell 50. From this upperdead center the pressure bell 50 is lowered by activating the elbowarrangement 40 or by activating the double elbow arrangement 130. Thislowering of the pressure bell 50 is continued until the laminate piece10 rests on the intermediary frame 70. Using the elbow arrangement 40 orthe double elbow arrangement 130 applies a mechanical pressure onto thepressure bell 50. An arrangement is provided in which the flat Laminatepiece 10 separates the pressure bell interior 55 pressure tight from thetool trough inferior 65.

In this arrangement the pressure bell 50 is in its lower dead center.The pressure bell 50 is lock able relative to the tool trough 60interior 55 pressure tool trough interior 65 in this lower dead center.Thus a first frame 77′ made from a massive steel plate is arranged atthe Tool trough 60 parallel and off set from a tool trough face wall63′. Two offset bore holes 78 are recessed in the upper bar of the firstframe 77′. In the same manner a second frame 77″ that is made from asmassive steel plate is arranged at the tool trough 60 in the same mannerparallel and offset from the other opposite tool trough face wall 63″.Two offset bore holes 78″ are recessed in the upper bar of the secondframe 77″ when the pressure bell 50 is in its lower dead center motoradjustable locking bolts 52′, 52″ 56′and 56″ can be inserted into thebore holes 78′ or 78″ wherein the locking bolts are arranged at thepressure bell 50. Thus the pressure bell 50 is arrested in its lockingposition relative to the tool trough 60 and the drive of the elbowarrangement 40 or of the double elbow arrangement 130 can be unloaded.

At this point in time an air pressure of the surrounding atmosphere isprovided in the pressure tight pressure bell interior 55 and in the tooltrough interior space 65 that is closed pressure tight. In a next step apressure medium pressure of less or equal 30 kPa is adjusted in thepressure bell interior 55 an in the tool trough interior 65 bynon-illustrated devices like e.g. a vacuum pump vacuum container andcontrol devices. Typically the originally provided atmospheric pressureis reduced by suitable devices. The two interior space 55 and 65 areevacuated. Typically the same absolute pressure medium pressure is setin both interior spaces. When required a slightly higher absolutepressure medium pressure can remain in the tool trough interior 65wherein the air pressure counter acts a sagging of the heated laminate10 that is caused by heating the laminate 10.

Now a condition is reached where

the table 80 is lowered to its lowered dead center within the tooltrough 60

A carrier plate 168 rests on the table top 82 of the table 80 thusarranged wherein at least one 3D-Substrate 3 that is to be coated restson the carrier plate;

An absolute pressure medium pressure of less or equal 30 kPa is providedin the pressure bell interior 55 and in the tool trough interior 65.

For further descriptions FIGS. 10, 11 and 12 are referred to whichrespectively show a sectional top view with the open tool trough in thiscondition.

In this arrangement there is a significant distance between the3D-Substrate 3 sitting on the lowered table 80 and the laminate piece 10resting on the intermediary frame 70 of the tool trough 60. For atypical table 80 with a rectangular table surface of 540 mm×360 mm thisdistance can be approximately 400 mm. In this arrangement a substantialclear intermediary space 90 is provided within the tool trough 60 whoseheight corresponds to this distance. As stated supra and illustrated inFIGS. 10-13 a horizontal box 66′ or 66″ is applied to the each tooltrough side wall 62′, 62″ wherein each horizontally oriented box definesa horizontally oriented retraction cavity 67′ or 67″ which is opentowards the interior 65 of the trough. In the retraction cavity 67′there is a first “half” displace able and horizontally oriented heatradiator arrangement 102 that can be moved into the trough interior 65.In the other retraction cavity 67″ there is a second “half” displaceable and horizontally heat radiator arranged 104 that can be displacedinto the trough interior 65. From the two “half” heat radiatorarrangement a horizontally oriented heat radiator arrangement 90 can beprovided in the clear intermediary space 90 as illustrated in FIGS. 11and 12. Alternatively the entire heat radiator arrangement 100 can bearranged in a non-illustrated larger retraction cavity and can be movedfrom this larger retraction cavity into the clear intermediary space 90within the tool trough 60. This alternative however has proven to bemore complicated and less useful.

At opposite insides of the tool trough face wall 63′ and 63″ and of theadjacent box face walls a respective support rail is arranged outside ofthe movement path of the table 80 wherein a respective edge profile ofthe “half” heat radiator arrangements 102 and 104 is engaged. The two“half” heat radiator arrangements 102 and 104 are displace able alongthe support rails. Moving these “half” heat radiator arrangements 102and 104 back and forth is caused by a motor driven threaded spindle 106which is run in a sealed manner through a box side wall 107 that isillustrated on the right side in FIG. 12 and supported in the oppositebox side wall 108. The gear motor 110 rotates the threaded spindle 106in a rotation direction which displaces the “half” heat radiatorarraignments 102 and 104 from their retraction cavity 67 and 67″ intothe trough interior 65 or in the opposite direction of rotation whichreturns the “half” heat radiator arrangement 102 and 104 from the troughinterior 65 back into their retraction cavities 67′ and 67″. The “half”heat radiator arrangements 102 and 104 that are displaced into tubeinterior 65 jointly form the heat radiator arrangement 100 which ishorizontally oriented according to the illustration according to FIG.12.

As evident from FIG. 11, the heat radiator arrangement 100 includes acarrier 112, on whose top side 114 the heat radiators 115 are arrangedand at whose bottom side 117 the heat radiators 118 are arranged. Theheat radiators 115 and 118 can be controlled differently. The powerrequired for operating the heat radiator 115 and 118 is provided by anenergy chain which is in turn connected with a cable which is runpressure right through a tool trough wall. Using the heat radiators 115the laminate 10 resting on the intermediary frame 70 can be radiated andheated in a controlled manner and the glue arranged at the bottom sideof the laminate 10 can be activated. Using the heat radiators 118 the3D-Substrate 3 that is arranged on the lowered table 80 and on thecarrier plate 158 can be radiated and heated in a controlled manner. Thearrangement of the horizontally oriented heat radiator arrangement 100in the intermediary space 90 between the laminate 10 sitting on theintermediary frame 70 and the 3D-Substrate 3 arranged on the loweredtable 80 and the independent and focused control of the upper heatradiators 115 and the independent and focused control of the lower heatradiators 118 provide options for a quick and controller heating of thelayer material 10 and the 3D-Substrate 3 which were not possible withthe convention TOM Process and its devices.

FIG. 12 illustrates an alternative heat radiator arrangement 100 whichincludes a carrier 112 on whose top side 114, schematically indicatedactivatable UV radiators 119 are arranged in addition to the heatradiators 115. Also these UV-radiators 119 radiate in the upwarddirection and their activation can be used to activate a UV-hardeningglue at the contact side of the laminate piece 10 in a controlledmanner.

Additional heat radiators 59 can be provided at an inside of the ceilingwall 54 of the pressure bell 50 as indicated in FIG. 13.

For heat radiators advantageously IR-flat radiators are used whichinclude a wide metal foil as a heat medium wherein the wide metal foilis embedded into a highly heat resistant material. When electricalcurrent pass through the mmetal foil heat to approximately 800° C. andgrows uniformly. A medium to long waveIR-radiation is emitted at wavelengths of approximately 2.6 to 9.6 μm. Using electronic control anydesired wavelength can be selected within this range and thus naydesired temperature can be selected at the material to be heated. Thusin particular plastic foils can be heated to temperatures of up to 800°C. It is a particular feature of these foil flat radiators that theyhave a very quick response. After switching them on a temperature of800° C. can be reached within 8-10 seconds. When turning them off thetemperature drops within 500 seconds from 800° to less than 200° C.Mini-Infrared-radiators of this type are already available in surfacesizes starting at approximately 120×500 mm from which the requiredradiator surface can be built. IR radiators of this type are sold forexample by KRELUS AG, 5042 Hirschthal, Switzerland.

For UV- radiators in particular UV-LED-Systems that operate with aircooling are suitable. Suitable UV LED systems are sold for example byHeraeus Noblelight GmbH, 63450 Hanau, DE. UV radiators of this typefacilitate activating and curing a UV hardening glue within a fewseconds.

According to the method according to the invention cycle times ofapproximately 60 seconds to 150 second, in particular of 60 seconds to120 seconds are desired. A heating time of approximately 15 seconds to40 seconds is available. The activatable heat radiators 115 and 118 andoptionally the activated UV radiators 119 shall be located within thetrough interior 65 during the heat up time.

After the laminate 10 has been heated to its deformation temperature byactivating the heat radiators 115 and optionally a UV hardening glue hasbeen activated at the laminate material 10 by activating the UVradiators 119 the “half” heat radiators arrangements 102 and 104 areretracted from the trough interior 65 into the retracation cavities 67′and 67″. The table 80 with the heated 3D-Substrate is raised until theheat 3D-Substrate 3 penetrates the heated laminate material 10 that isclamped between the intermediary frame 70 and the seal surface 58 at thepressure bell 50. The heated laminate material 10 is moved along in atent shape by the heated 3D-substrate 3 and attaches to the contour ofthe 3D-Substrate 3 as indicated in FIG. 14. At this point in time thereis a reduced pressure medium pressure of less or equal 30 kPa in thetrough interior 65 and in the pressure bell interior 55. After the table80 has reached its upper dead center the pressure medium pressure in thepressure bell interior 55 is increased. First air at ambient pressure isintroduced into the pressure bell interior cavity 55; subsequently fluidpressure medium, advantageously compressed air is introduced so that apressure medium pressure of 2-18 bar is set in the pressure bellinterior 55. These pressure medium pressure values are absolute values.A pressure medium pressure of 2 bar therefore is higher by approximately1 bar than the surrounding atmospheric pressure. Advantageously apressure medium pressure of 3 to 15 bar is set in the pressure bellinterior 55. The pressure medium pressure in the trough interior 65 isfurthermore kept at a value of less or equal 30 kPa.

Increasing the pressure medium pressure in the pressure bell interior 55attaches the heated laminate 10 closely and with great detail to thecontour of the 3D-Substrate 3 which is schematically illustrated in FIG.14. The glue arranged at the contact side of the laminate 10 isactivated by the preceding controlled heating and optionally controlledUV radiation so that good adhesion between the activated glue and thealso activated 3D-substrate 3 can be obtained. The increased pressuremedium pressure is maintained until the coating is completed. This cantake several seconds, for example up to 30 seconds.

Thereafter atmospheric pressure is set in the trough interior 65 and inthe pressure bell interior 55. The pressure bell 50 is raised. Thetransport frame 122 contimues to contact the seal surface 58 of the ofthe pressure bell 50 and imparts a suction force upon the laminate edge.During initial rasing of the transport frame 122 the edge of thelaminate is separated from the comparatively cold intermediary framecoated pressure medium pressure 70; the arrangement illustrated in FIG.15 is obtained. The laminate 10 contacts the coated 3D-Substrate 9 sothat also fine details are reproduced. Superfluous laminate 14 isapplied to the surface of the carrier plate 168; a blown up detail viewshows the product thus obtained.

The lifting and pivot arms 75 are described supra are activated, theiractivated electromagnets 76 raise the carrier plate 168. The slides 74′,74″ are activated and the activated lifting and pivot arms 75 arrangedat the moved slides 74′, 74″ transport the carrier plate 168 with thecoated product from the forming tool 20 to the retaining station 163, asillustrated in FIGS. 16, 22 and 23. An activation of the second slide154 of the transport path 150 transports the second transport pallet 157with the carrier plate 168 and the coated product from the retainingstation 163 into the retrieval station 165. There the coated product canbe retrieved and processed as required. The transport plate 167 andcarrier plate 168 can be introduced by hand or by a robot into theplacement station 160 to start a coating cycle.

EMBODIMENTS

The subsequent embodiments illustrate the invention in more detailwithout limiting its scope and spirit

Embodiment 1

A forming tool is used as illustrated in FIGS. 2-5 and described suprain detail.

A 3D-substrate is used as illustrated in FIGS. 1A and 1B and describedsupra in detail.

The 3D-Substrate is firmly attached on a rectangular carrier plate. Thecarrier plate has dimensions of 530 mm×350 mm and is made frompolyamide. The carrier plate is coated with TEFLON®.

A 1 mm thick structured foil made from a blend of TPU and PMMA which isdied solid black is used for a laminate wherein the structured foil isprovided with a diamond structure on its visible side by negativeprinting. A structured foil of this type is sold by EXEL GMBH, 81301Rohrdorf, DE.

DESMOMELT 530 sold by Bayer Material Science is used as a glue. This isa granular product that is thermally activate able at or above 75° C.the granulate is processed in an extruder into a pre plasticized meltwhich is applied by a slotted nozzle on the contact side of thestructure foil in a limited surface section which will contact thesurface of the 3D-Substrate to be coated. Thereafter cooling and dryingis performed. The glue layer arranged at the structured foil has a layerthickness of 60 μm and remains useable and thermally activate able alsoalter a storage time of more than 3 months. The laminate thus preparedis thus cut to sizes of 550 mm×370 mm.

At the forming tool the pressure bell moves into its upper dead center.The table arranged within the tool trough has a rectangular tablesurface of 540 mm×360 mm and is moved into its upper dead center. Herethe table top is directly below the intermediary frame which forms theupper termination of the tool trough. Using the transport path thecarrier plate retaining the 3D-substrate has been moved over theintermediary frame and has been lowered there by the activated liftingand pivot arms into the closed cut out within the intermediary frame.The carrier plate rests on the table top. The carrier plate fitsprecisely into the cut out. The separation gap is less then 1 mm.

The laminate piece that is provided with the described glue and whichhas ambient temperature is gripped by the transport frame by suctionforce and transported by the transport frame into a position below thepressure bell that is in its upper dead center. The transport framewhich continues to support the laminate piece is applied to acircumferential seal surface at the edge of the pressure bell and fixedat this location.

Each “half” heat radiator arrangement is arranged in its retractioncavity. The described IR flat radiators are used as heat radiators whichinclude a metal foil that can be caused to glow as heat elements. Theheat radiators are not activated. The table supporting the carrier platewith the retained 3D-substrate is moved into its lower dead center. Thecarrier plate with its transport frame that continues to support thelaminate piece is moved into lower dead center; the laminate piececontacts the intermediary frame and assumes a horizontal orientation. Anarrangement is provided where the laminate piece is clamped between thepressure bell and the tool shaft and separates the pressure bellinterior space pressure tight from the interior of the trough.

The pressure bell interior space is connected through a large volumevacuum hose and controlled organs at a smaller vacuum container. Thetrough interior is connected through a large volume vacuum conductor andcontrol devices with a larger vacuum container, but also two vacuumcontainers can be provided in this application.

The vacuum containers have been evacuated in advance by a vacuum pump toa residual pressure of approximately 5 kPa, (approximately 40 Torr). Byadjusting the control devices the pressure bell interior and the troughinterior are connected with the respectively associated evacuatedcontainers. In the trough interior a pressure medium pressure ofapproximately 10 kPa (approximately 80 Torr) is set. In the pressurebell interior a slightly smaller pressure medium pressure is set.

The 3D-substrate that is arranged on the lowered table is about 400 mmaway from the clamped layer material. The two “half” radiatorarrangements are moved in to the clear intermediary space thus providedthus form the heat radiator arrangement which fills the tool troughcross section on most but not completely. The heat radiators areactivated and the upward heat radiators are operated with almost maximumpower. The downward radiating heat radiators are operated with reducedpower. After approximately 25 seconds a temperature of approx. 180° C.is measured by the heat radiator pyrometer. The glue layer has beenheated beyond its activation temperature. The 3D-Substrate surfacereaches a temperature of approximately 80° C. The heat radiators aredeactivated and the “half” heat radiator arrangements are retracted intotheir respective retraction space.

While maintaining the reduced pressure medium pressure in both interiorspaces the table is raised slowly until it reaches its upper deadcenter. The 3D-Substrate penetrates the plane of the clamped laminateand moves the laminate along in a tent shape. The activated glue layercontacts the warm 3D-Substrate surface and reacts and bonds therewith.In the sense of a positive forming the heated laminate is applied to thewarm 3D-Substrate surface incrementally and gently.

After the table has reached its top dead center the reduced pressuremedium pressure is maintained in the trough interior and the pressurebell interior is first ventilated with the surrounding ambient pressureand subsequently loaded with compressed air at a pressure mediumpressure of 12 bar. The hot laminate is molded closely and precisely atthe contour of the 3D-Substrate and applied to the free surface of thecarrier plate. The high pressure medium pressure is maintained forapproximately 12 sec in order to obtain good adhesion of the glue joint.There after the trough interior is ventilated and the pressure bellinterior space is ventilated. In both spaces ambient atmosphericpressure is set. Thus also the formed laminate and the 3D-Substrate arecooled below the activation temperature of the glue and at least another10 seconds of cooling is performed.

Thereafter the pressure bell and transport frame that is still connectedtherewith is raised. The suction force originating from the transportframe separates the laminate edge without residue from the contactsurface at the intermediary frame. Another lifting of the pressure bellseparates the transport frame from the Laminate edge. And activation ofthe lifting and pivot arms raises the carrier plate above the level ofthe Intermediary frame and eventually moves the carrier plate with thecoated product out of the forming tool. A time period of approximately52 seconds has lapsed since the carrier plate with the 3D-Substrate tobe coated has been introduced in to the forming tool.

The coated 3D-substrate with the overhanging laminate is separated fromthe carrier plate. The product thus obtained can be cut to size andprocessed by a 5 axis milling robot. Alternatively the overhanginglaminate can be cut off by a moving laser beam. The structured foilcontacts the coated body thus obtained smoothly without voids also atthe concave cavity at the top side of the body. The structured foil alsoreaches around the circumferential bar. Enters the circumferentialgroove at the bar and coats the groove and contacts the face of the barfirmly adhering. No interruption of the glue surface can be found atthis face at the top side of the coated body and in its concave cavityno distortion of the structure of the structured foil can be found.

Embodiment 2

The embodiment according to claim 1 is essentially repeated. As adifference therefrom a blank made from the structured foil recited suprais used which is provided at its contact side on its entire surface witha dry layer made from the same glue. This glue has a size whichcorresponds essentially to the cover able surface at the 3D-Substrate.This blank adheres by an adhesion glue that can be removed withoutresiduals at a piece of transfer foil. A standard PP foil with a layerthickness of 300 μm is used as a transfer foil. The transfer foil piecehas dimensions so that it can be clamped between the transport frame atthe pressure bell and the intermediary frame at the tool trough.

The evacuation, heating, loading with high pressure fluid, subsequentventilation of the spaces, cooling of the product and moving the productout of the forming tool are performed under the stated conditions. Atthe product the coated body includes an edge strip with excess structurefoil with a width of approximately 2-4 mm. This edge strip can beremoved easily. After removing the transfer foil a product is obtainedthat corresponds to the product according to claim 1, however a muchsmaller amount of structured foil has been used.

What is claimed is:
 1. A device for producing a 3D-substrate that iscoated with a laminate, the device comprising: a forming tool including,a lower stationary tool half which includes a tool trough that envelopsa tool trough interior space in which a lowerable table is arranged, anupper tool half which includes a pressure bell that envelops a pressurebell interior space, wherein the pressure bell is arrangeable in aclosed pressure position adjacent to the tool trough and in a raisedrelease position that is remote from the tool trough, wherein anarrangement is providable in the raised release position of the pressurebell, so that a 3D-substrate that is to be coated is insertable into theforming tool and the 3D-substrate is fixable to the lowerable table inthe tool trough and the lowerable table is lowerable to a bottom deadcenter, so that a one layer or multi-layer initially flat laminate thathas a visible side and an opposite contact side or a flexible transferfoil that is provided with a blank made from the laminate is applicableat a circumferential edge of the pressure bell or adjacent theretowherein an arrangement is providable in the closed pressure position ofthe pressure bell, so that the laminate or the transfer foil separatesthe tool trough interior space and the pressure bell interior spacepressure tight from each other, so that a pressure medium pressure ofless than or equal to 30 kPa is initially providable in the tool troughinterior space, so that an initial vacuum of less than or equal to 30kPa is providable in the pressure bell interior space and subsequently apressure medium pressure of 2-18 bar is providable in the pressure bellinterior space by introducing a fluid pressure medium, so that thelaminate is heatable while the tool trough interior space and thepressure bell interior space are provided with a pressure mediumpressure of less than or equal to 30 kPa, wherein the tool troughincludes at least one retraction cavity for at least one movable heatradiator arrangement which includes at least one upward radiating heatradiator, wherein the at least one movable heat radiator arrangement ismovable in the closed pressure position of the pressure bell and afterthe pressure medium pressure is set at less than or equal to 30 kPawithin the tool trough interior space from the at least one retractioncavity into an intermediary space between the laminate and the 3Dsubstrate to be coated and the laminate is heatable in a controlledmanner by the at least one upward radiating heat radiator to form aheated laminate, wherein the heated laminate is applicable over a gluelayer to the 3D-substrate and coatable thereto, wherein ambient pressureis providable in the tool trough interior space and the pressure bellinterior space and renders the pressure bell separable from the tooltrough by lifting the pressure bell from the tool trough and the3D-substrate that is coated with the laminate is removable from the tooltrough interior space, wherein the glue layer that is provided withactivatable glue is arranged at a contact side of the laminate and theglue layer arranged at the laminate contact side is activatable byactivating the at least one upward radiating heat radiator, wherein themovable heat radiator arrangement is additionally provided with at leastone activatable downward radiating heat radiator, wherein the movableheat radiator arrangement is introducible into the intermediary spacebetween the laminate material and the 3D-substrate so that a surface ofthe 3D-substrate is heatable in a controlled manner by the at least onedownward radiating heat radiator, wherein the at least one movable heatradiator arrangement is retractable into the retraction cavity aftercompletion of heat treatments, wherein the 3D-substrate is configured topenetrate a laminate plane in an upper dead center of the lowerabletable and move the heated laminate along in a tent shape while apressure medium pressure of less than or equal to 30 kPa is maintainedin the pressure bell interior space and in the tool trough interiorspace wherein the pressure bell interior space is pressure configured tobe sealed from the tool trough interior space by the laminate while thelowerable table is being raised from the lower dead center to the upperdead center, wherein a fluid pressure medium or compressed air isintroducible into the pressure bell interior space after the lowerabletable has reached the upper dead center in order to adjust a pressuremedium pressure of 2-18 bar in the pressure bell interior space whilemaintaining a pressure medium pressure of less than or equal to 30 kPain the tool trough interior space so that the laminate is pressed andcoated onto the substrate above the at least one movable heat radiatorarrangement, wherein a respective box is applied at two opposite sidewalls of the tool trough, wherein the box respectively defines aretraction cavity for a displaceable half heat radiator arrangement, andwherein two of the half heat radiator arrangements form the heatradiator arrangement after insertion into the trough interior.
 2. Thedevice according to claim 1, wherein the tool trough includes at leastone horizontal or substantially horizontally oriented retraction cavityfor at least one displaceable and horizontal or substantiallyhorizontally arranged heat radiator arrangement which is configured withactivatable upward radiating radiators and with activatable downwardradiating heat radiators.
 3. The device according to claim 1, wherein ahorizontal or substantially horizontal box is applied at two oppositeside walls of the tool trough wherein the box defines horizontallyoriented or substantially horizontally oriented retraction cavities formovable half heat radiator arrangements, and wherein two of the movablehalf heat radiator arrangements form a horizontal or substantiallyhorizontal arranged heat radiator arrangement after insertion into thetrough interior.
 4. The device according to claim 1, wherein the heatradiator arrangement includes a carrier, wherein a top side of thecarrier includes activatable upward radiating heat radiators andadditional activatable upward radiating UV radiators.
 5. The deviceaccording to claim 1, wherein IR flat radiators are used for heatradiators, wherein a heat element of the IR flat radiators includesstrips made from a temperature resistant metal foil that are arrangedparallel adjacent to each other and that form a continuous conductor,wherein the metal foil is forcible to glow when an electrical currentpasses through so that the metal foil reaches a temperature of up toapproximately 800° C., and wherein medium wave length to long wavelength IR radiation is emitted in a wave length range of 2.6 to 9.6 μm.6. The device according to claim 1, wherein the lowerable table includesa rectangular table surface with dimensions of approximately 540mm×approximately 360 mm up to approximately 800 mm×approximately 600 mm.7. The device according to claim 1, wherein the at least one movableheat radiator arrangement includes two heat radiators that are movablein opposite directions perpendicular to the movement direction of thelowerable table.
 8. The device according to claim 1, wherein the upperdead center of the lowerable table is above the at least one movableheat radiator arrangement.
 9. A device for producing a 3D-substrate thatis coated with a laminate, the device comprising: a forming toolincluding, a lower stationary tool half which includes a tool troughthat envelops a tool trough interior space in which a lowerable table isarranged, an upper tool half which includes a pressure bell thatenvelops a pressure bell interior space, wherein the pressure bell isarrangeable in a closed pressure position adjacent to the tool troughand in a raised release position that is remote from the tool trough,wherein an arrangement is providable in the raised release position ofthe pressure bell, so that a 3D-substrate that is to be coated isinsertable into the forming tool and the 3D-substrate is fixable to thelowerable table in the tool trough and the lowerable table is lowerableto a bottom dead center, so that a one layer or multi-layer initiallyflat laminate that has a visible side and an opposite contact side or aflexible transfer foil that is provided with a blank made from thelaminate is applicable at a circumferential edge of the pressure bell oradjacent thereto wherein an arrangement is providable in the closedpressure position of the pressure bell, so that the laminate or thetransfer foil separates the tool trough interior space and the pressurebell interior space pressure tight from each other, so that a pressuremedium pressure of less than or equal to 30 kPa is initially providablein the tool trough interior space, so that an initial vacuum of lessthan or equal to 30 kPa is providable in the pressure bell interiorspace and subsequently a pressure medium pressure of 2-18 bar isprovidable in the pressure bell interior space by introducing a fluidpressure medium, so that the laminate is heatable while the tool troughinterior space and the pressure bell interior space are provided with apressure medium pressure of less than or equal to 30 kPa, wherein thetool trough includes at least one retraction cavity for at least onemovable heat radiator arrangement which includes at least one upwardradiating heat radiator, wherein the at least one movable heat radiatorarrangement is movable in the closed pressure position of the pressurebell and after the pressure medium pressure is set at less than or equalto 30 kPa within the tool trough interior space from the at least oneretraction cavity into an intermediary space between the laminate andthe 3D substrate to be coated and the laminate is heatable in acontrolled manner by the at least one upward radiating heat radiator toform a heated laminate, wherein the heated laminate is applicable over aglue layer to the 3D-substrate and coatable thereto, wherein ambientpressure is providable in the tool trough interior space and thepressure bell interior space and renders the pressure bell separablefrom the tool trough by lifting the pressure bell from the tool troughand the 3D-substrate that is coated with the laminate is removable fromthe tool trough interior space, wherein the glue layer that is providedwith activatable glue is arranged at a contact side of the laminate andthe glue layer arranged at the laminate contact side is activatable byactivating the at least one upward radiating heat radiator, wherein themovable heat radiator arrangement is additionally provided with at leastone activatable downward radiating heat radiator, wherein the movableheat radiator arrangement is introducible into the intermediary spacebetween the laminate material and the 3D-substrate so that a surface ofthe 3D-substrate is heatable in a controlled manner by the at least onedownward radiating heat radiator, wherein the at least one movable heatradiator arrangement is retractable into the retraction cavity aftercompletion of heat treatments, wherein the 3D-substrate is configured topenetrate a laminate plane in an upper dead center of the lowerabletable and move the heated laminate along in a tent shape while apressure medium pressure of less than or equal to 30 kPa is maintainedin the pressure bell interior space and in the tool trough interiorspace wherein the pressure bell interior space is pressure configured tobe sealed from the tool trough interior space by the laminate while thelowerable table is being raised from the lower dead center to the upperdead center, wherein a fluid pressure medium or compressed air isintroducible into the pressure bell interior space after the lowerabletable has reached the upper dead center in order to adjust a pressuremedium pressure of 2-18 bar in the pressure bell interior space whilemaintaining a pressure medium pressure of less than or equal to 30 kPain the tool trough interior space so that the laminate is pressed andcoated onto the substrate above the at least one movable heat radiatorarrangement, wherein a respective box is applied at two opposite sidewalls of the tool trough, wherein the box respectively defines aretraction cavity for a displaceable half heat radiator arrangement,wherein two of the half heat radiator arrangements form the heatradiator arrangement after insertion into the trough interior; atransport arrangement for laminate pieces that are cut to size isprovided, the transport arrangement including: a magazine which includesa stock of the laminate material pieces, a transport frame that ismovable over the magazine and that lifts and retains the laminate piecethrough a vacuum, wherein the transport frame that supports the laminatepiece is movable below the pressure bell in its top dead center andapplicable at this location to a circumferential seal surface of thepressure bell, and wherein the transport frame contacting the pressurebell retains the laminate piece when the pressure bell is lowered.
 10. Adevice for producing a 3D-substrate that is coated with a laminate, thedevice comprising: a forming tool including, a lower stationary toolhalf which includes a tool trough that envelops a tool trough interiorspace in which a lowerable table is arranged, an upper tool half whichincludes a pressure bell that envelops a pressure bell interior space,wherein the pressure bell is arrangeable in a closed pressure positionadjacent to the tool trough and in a raised release position that isremote from the tool trough, wherein an arrangement is providable in theraised release position of the pressure bell, so that a 3D-substratethat is to be coated is insertable into the forming tool and the3D-substrate is fixable to the lowerable table in the tool trough andthe lowerable table is lowerable to a bottom dead center, so that a onelayer or multi-layer initially flat laminate that has a visible side andan opposite contact side or a flexible transfer foil that is providedwith a blank made from the laminate is applicable at a circumferentialedge of the pressure bell or adjacent thereto wherein an arrangement isprovidable in the closed pressure position of the pressure bell, so thatthe laminate or the transfer foil separates the tool trough interiorspace and the pressure bell interior space pressure tight from eachother, so that a pressure medium pressure of less than or equal to 30kPa is initially providable in the tool trough interior space, so thatan initial vacuum of less than or equal to 30 kPa is providable in thepressure bell interior space and subsequently a pressure medium pressureof 2-18 bar is providable in the pressure bell interior space byintroducing a fluid pressure medium, so that the laminate is heatablewhile the tool trough interior space and the pressure bell interiorspace are provided with a pressure medium pressure of less than or equalto 30 kPa, wherein the tool trough includes at least one retractioncavity for at least one movable heat radiator arrangement which includesat least one upward radiating heat radiator, wherein the at least onemovable heat radiator arrangement is movable in the closed pressureposition of the pressure bell and after the pressure medium pressure isset at less than or equal to 30 kPa within the tool trough interiorspace from the at least one retraction cavity into an intermediary spacebetween the laminate and the 3D substrate to be coated and the laminateis heatable in a controlled manner by the at least one upward radiatingheat radiator to form a heated laminate, wherein the heated laminate isapplicable over a glue layer to the 3D-substrate and coatable thereto,wherein ambient pressure is providable in the tool trough interior spaceand the pressure bell interior space and renders the pressure bellseparable from the tool trough by lifting the pressure bell from thetool trough and the 3D-substrate that is coated with the laminate isremovable from the tool trough interior space, wherein the glue layerthat is provided with activatable glue is arranged at a contact side ofthe laminate and the glue layer arranged at the laminate contact side isactivatable by activating the at least one upward radiating heatradiator, wherein the movable heat radiator arrangement is additionallyprovided with at least one activatable downward radiating heat radiator,wherein the movable heat radiator arrangement is introducible into theintermediary space between the laminate material and the 3D-substrate sothat a surface of the 3D-substrate is heatable in a controlled manner bythe at least one downward radiating heat radiator, wherein the at leastone movable heat radiator arrangement is retractable into the retractioncavity after completion of heat treatments, wherein the 3D-substrate isconfigured to penetrate a laminate plane in an upper dead center of thelowerable table and move the heated laminate along in a tent shape whilea pressure medium pressure of less than or equal to 30 kPa is maintainedin the pressure bell interior space and in the tool trough interiorspace wherein the pressure bell interior space is pressure configured tobe sealed from the tool trough interior space by the laminate while thelowerable table is being raised from the lower dead center to the upperdead center, and wherein a fluid pressure medium or compressed air isintroducible into the pressure bell interior space after the lowerabletable has reached the upper dead center in order to adjust a pressuremedium pressure of 2-18 bar in the pressure bell interior space whilemaintaining a pressure medium pressure of less than or equal to 30 kPain the tool trough interior space so that the laminate is pressed andcoated onto the substrate above the at least one movable heat radiatorarrangement, wherein a respective box is applied at two opposite sidewalls of the tool trough, wherein the box respectively defines aretraction cavity for a displaceable half heat radiator arrangement,wherein two of the half heat radiator arrangements form the heatradiator arrangement after insertion into the trough interior; atransport path for the 3D-substrate to be coated, the transport pathincluding: a rail that is stationary and fixed at the tool trough andprovided with a linear arrangement, wherein at least one slide ismovable along the rail, wherein the slide transports transport platesfrom an application station to a retaining station and transports thetransport plates from the retaining station to a retrieval station,wherein a carrier plate is applicable to the transport plate arranged inthe placement station, wherein the carrier plate supports a 3D-substrateto be coated or plural 3D-substrates to be coated, wherein lifting andpivot arms mounted at movable slides transport the carrier plate that isarranged in the retaining station and retains one or plural3D-substrates to be coated from the retaining station into a positionbelow the raised pressure bell and place the 3D-substrate within a cutout at an intermediary frame at the tool trough on a table top of thetable that is in its upper dead center, and wherein the coated productis retrievable in the retrieval station.
 11. The device according toclaim 10, wherein the carrier plate is made from a plastic material,wherein the carrier plate is coated with a release agent, wherein thecarrier plate has a polygonal surface, and wherein magneticallyresponsive material is arranged in corner portions of the polygonalsurface.
 12. The device according to claim 10, wherein the lifting andpivot arms transport the carrier plate that supports one or plural3D-substrates to be coated from the retaining station into a positionbelow the raised pressure bell, wherein an activatable electro magnet isattached at each free end of the lifting and pivot arms wherein theactivatable electromagnet is configured to contact a corner portion ofthe carrier plate and the carrier plate is liftable when the electromagnets are activated.
 13. A device for producing a 3D-substrate that iscoated with a laminate, the device comprising: a forming tool including,a lower stationary tool half which includes a tool trough that envelopsa tool trough interior space in which a lowerable table is arranged, anupper tool half which includes a pressure bell that envelops a pressurebell interior space, wherein the pressure bell is arrangeable in aclosed pressure position adjacent to the tool trough and in a raisedrelease position that is remote from the tool trough, wherein anarrangement is providable in the raised release position of the pressurebell, so that a 3D-substrate that is to be coated is insertable into theforming tool and the 3D-substrate is fixable to the lowerable table inthe tool trough and the lowerable table is lowerable to a bottom deadcenter, so that a one layer or multi-layer initially flat laminate thathas a visible side and an opposite contact side or a flexible transferfoil that is provided with a blank made from the laminate is applicableat a circumferential edge of the pressure bell or adjacent theretowherein an arrangement is providable in the closed pressure position ofthe pressure bell, so that the laminate or the transfer foil separatesthe tool trough interior space and the pressure bell interior spacepressure tight from each other, so that a pressure medium pressure ofless than or equal to 30 kPa is initially providable in the tool troughinterior space, so that an initial vacuum of less than or equal to 30kPa is providable in the pressure bell interior space and subsequently apressure medium pressure of 2-18 bar is providable in the pressure bellinterior space by introducing a fluid pressure medium, so that thelaminate is heatable while the tool trough interior space and thepressure bell interior space are provided with a pressure mediumpressure of less than or equal to 30 kPa, wherein the tool troughincludes at least one retraction cavity for at least one movable heatradiator arrangement which includes at least one upward radiating heatradiator, wherein the at least one movable heat radiator arrangement ismovable in the closed pressure position of the pressure bell and afterthe pressure medium pressure is set at less than or equal to 30 kPawithin the tool trough interior space from the at least one retractioncavity into an intermediary space between the laminate and the 3Dsubstrate to be coated and the laminate is heatable in a controlledmanner by the at least one upward radiating heat radiator to form aheated laminate, wherein the heated laminate is applicable over a gluelayer to the 3D-substrate and coatable thereto, wherein ambient pressureis providable in the tool trough interior space and the pressure bellinterior space and renders the pressure bell separable from the tooltrough by lifting the pressure bell from the tool trough and the3D-substrate that is coated with the laminate is removable from the tooltrough interior space, wherein the glue layer that is provided withactivatable glue is arranged at a contact side of the laminate and theglue layer arranged at the laminate contact side is activatable byactivating the at least one upward radiating heat radiator, wherein themovable heat radiator arrangement is additionally provided with at leastone activatable downward radiating heat radiator, wherein the movableheat radiator arrangement is introducible into the intermediary spacebetween the laminate material and the 3D-substrate so that a surface ofthe 3D-substrate is heatable in a controlled manner by the at least onedownward radiating heat radiator. wherein the at least one movable heatradiator arrangement is retractable into the retraction cavity aftercompletion of heat treatments, wherein the 3D-substrate is configured topenetrate a laminate plane in an upper dead center of the lowerabletable and move the heated laminate along in a tent shape while apressure medium pressure of less than or equal to 30 kPa is maintainedin the pressure bell interior space and in the tool trough interiorspace wherein the pressure bell interior space is pressure configured tobe sealed from the tool trough interior space by the laminate while thelowerable table is being raised from the lower dead center to the upperdead center, wherein a fluid pressure medium or compressed air isintroducible into the pressure bell interior space after the lowerabletable has reached the upper dead center in order to adjust a pressuremedium pressure of 2-18 bar in the pressure bell interior space whilemaintaining a pressure medium pressure of less than or equal to 30 kPain the tool trough interior space so that the laminate is pressed andcoated onto the substrate above the at least one movable heat radiatorarrangement, wherein a respective box is applied at two opposite sidewalls of the tool trough, wherein the box respectively defines aretraction cavity for a displaceable half heat radiator arrangement,wherein two of the half heat radiator arrangements form the heatradiator arrangement after insertion into the trough interior, whereinthe pressure bell is arrestable or interlockable in its lower deadcenter by motor driven adjustable locking bolts that are arranged at thepressure bell, and wherein the pressure bell is arrestable orinterlockable at a frame that is fixed at the tool trough and made froma steel plate.
 14. A device for producing a 3D-substrate that is coatedwith a laminate, the device comprising: a forming tool including, alower stationary tool half which includes a tool trough that envelops atool trough interior space in which a lowerable table is arranged, anupper tool half which includes a pressure bell that envelops a pressurebell interior space, wherein the pressure bell is arrangeable in aclosed pressure position adjacent to the tool trough and in a raisedrelease position that is remote from the tool trough, wherein anarrangement is providable in the raised release position of the pressurebell, so that a 3D-substrate that is to be coated is insertable into theforming tool and the 3D-substrate is fixable to the lowerable table inthe tool trough and the lowerable table is lowerable to a bottom deadcenter, so that a one layer or multi-layer initially flat laminate thathas a visible side and an opposite contact side or a flexible transferfoil that is provided with a blank made from the laminate is applicableat a circumferential edge of the pressure bell or adjacent theretowherein an arrangement is providable in the closed pressure position ofthe pressure bell, so that the laminate or the transfer foil separatesthe tool trough interior space and the pressure bell interior spacepressure tight from each other, so that a pressure medium pressure ofless than or equal to 30 kPa is initially providable in the tool troughinterior space, so that an initial vacuum of less than or equal to 30kPa is providable in the pressure bell interior space and subsequently apressure medium pressure of 2-18 bar is providable in the pressure bellinterior space by introducing a fluid pressure medium, so that thelaminate is heatable while the tool trough interior space and thepressure bell interior space are provided with a pressure mediumpressure of less than or equal to 30 kPa, wherein the tool troughincludes at least one retraction cavity for at least one movable heatradiator arrangement which includes at least one upward radiating heatradiator, wherein the at least one movable heat radiator arrangement ismovable in the closed pressure position of the pressure bell and afterthe pressure medium pressure is set at less than or equal to 30 kPawithin the tool trough interior space from the at least one retractioncavity into an intermediary space between the laminate and the 3Dsubstrate to be coated and the laminate is heatable in a controlledmanner by the at least one upward radiating heat radiator to form aheated laminate, wherein the heated laminate is applicable over a gluelayer to the 3D-substrate and coatable thereto, wherein ambient pressureis providable in the tool trough interior space and the pressure bellinterior space and renders the pressure bell separable from the tooltrough by lifting the pressure bell from the tool trough and the3D-substrate that is coated with the laminate is removable from the tooltrough interior space, wherein the glue layer that is provided withactivatable glue is arranged at a contact side of the laminate and theglue layer arranged at the laminate contact side is activatable byactivating the at least one upward radiating heat radiator, wherein themovable heat radiator arrangement is additionally provided with at leastone activatable downward radiating heat radiator, wherein the movableheat radiator arrangement is introducible into the intermediary spacebetween the laminate material and the 3D-substrate so that a surface ofthe 3D-substrate is heatable in a controlled manner by the at least onedownward radiating heat radiator, wherein the at least one movable heatradiator arrangement is retractable into the retraction cavity aftercompletion of heat treatments, wherein the 3D-substrate is configured topenetrate a laminate plane in an upper dead center of the lowerabletable and move the heated laminate along in a tent shape while apressure medium pressure of less than or equal to 30 kPa is maintainedin the pressure bell interior space and in the tool trough interiorspace wherein the pressure bell interior space is pressure configured tobe sealed from the tool trough interior space by the laminate while thelowerable table is being raised from the lower dead center to the upperdead center, wherein a fluid pressure medium or compressed air isintroducible into the pressure bell interior space after the lowerabletable has reached the upper dead center in order to adjust a pressuremedium pressure of 2-18 bar in the pressure bell interior space whilemaintaining a pressure medium pressure of less than or equal to 30 kPain the tool trough interior space so that the laminate is pressed andcoated onto the substrate above the at least one movable heat radiatorarrangement, wherein a respective box is applied at two opposite sidewalls of the tool trough, wherein the box respectively defines aretraction cavity for a displaceable half heat radiator arrangement,wherein two of the half heat radiator arrangements form the heatradiator arrangement after insertion into the trough interior, wherein adouble elbow arrangement is provided for lifting the pressure bell fromits lower dead center to its upper dead center, wherein the double elbowarrangement includes two elbow levers respectively provided with aseparate drive, and wherein blocking one elbow lever and activating theother elbow lever renders the pressure bell pivotable into a serviceposition in which the circumferential seal surface at an edge of thepressure bell is essentially vertically oriented.